Methods of creating a textured breast implant

Abstract

Methods for texturing surgical implants, for example, breast implants, are provided. The methods include applying a tacky layer onto an implant shell, creating a micrometer-scale pattern of sacrificial material on the tacky layer, and thereafter, removing the sacrificial material from the tacky layer to obtain a textured layer. Multiple textured layers can be formed on the implant shell. Further, the micrometer-scale pattern can be formed using a printing mechanism and a 3D printing technique, such as a solid freeform fabrication or a layer manufacturing technique.

What is claimed is: 
     
         1 . A method for creating a textured breast implant shell using sacrificial material, the method comprising:
 creating a first layer of a micrometer-scale pattern of the sacrificial material on a breast implant shell via a three-dimensional printing process;   applying a binder to the first layer;   creating a second micrometer-scale pattern of an additional amount of the sacrificial material on the first layer via a three-dimensional printing process; and   removing the sacrificial material from the breast implant shell to obtain a textured surface, the textured surface being configured to permit ingrowth of cells into the breast implant shell.   
     
     
         2 . The method of  claim 1 , further comprising curing the first layer before the creating the second micrometer-scale pattern. 
     
     
         3 . The method of  claim 2 , further comprising removing the sacrificial material from the first layer before the creating the second micrometer-scale pattern. 
     
     
         4 . The method of  claim 1 , further comprising applying a tacky layer onto the first layer. 
     
     
         5 . The method of  claim 4 , further comprising curing the tacky layer to form a second layer. 
     
     
         6 . The method of  claim 1 , wherein the sacrificial material comprises a sugar. 
     
     
         7 . The method of  claim 1 , wherein the sacrificial material comprises a sugar and a binder in an aqueous solution or alcohol. 
     
     
         8 . The method of  claim 1 , further comprising obtaining a predetermined thickness of layers by applying additional alternating layers of a tacky layer and sacrificial material. 
     
     
         9 . The method of  claim 8 , wherein the predetermined thickness varies in various regions on the breast implant shell. 
     
     
         10 . The method of  claim 1 , wherein the first or second micrometer-scale patterns is one of a closely packed hexagonal pattern, a nested/tangent circle pattern, or a rectangle pattern. 
     
     
         11 . The method of  claim 1 , wherein the three-dimensional printing process utilizes binder deposition printing. 
     
     
         12 . The method of  claim 1 , wherein the removing the sacrificial material from the breast implant shell comprises placing the breast implant shell in a water bath and rubbing the sacrificial material from the breast implant shell. 
     
     
         13 . The method of  claim 1 , wherein the creating comprises forming the micrometer-scale pattern using a solid freeform fabrication (SFF) or layer manufacturing (LM) technique. 
     
     
         14 . A method for creating a textured breast implant shell having a plurality of textured layers thereon, method comprising repeatedly, for each textured layer, performing the steps of:
 applying a tacky layer onto the breast implant shell;   creating a micrometer-scale pattern of sacrificial material on the tacky layer;   curing the tacky layer; and   removing the sacrificial material from the tacky layer to obtain a textured layer.   
     
     
         15 . The method of  claim 14 , further comprising obtaining a predetermined thickness of the textured layer by applying the tacky layer and the sacrificial material alternately. 
     
     
         16 . The method of  claim 15 , wherein the predetermined thickness varies in various regions on the textured layer. 
     
     
         17 . The method of  claim 14 , wherein the sacrificial material comprises a sugar. 
     
     
         18 . The method of  claim 14 , wherein the micrometer-scale pattern comprises a hexagonal pattern, a circle pattern, or a rectangle pattern. 
     
     
         19 . The method of  claim 14 , wherein the removing the sacrificial material comprises placing the breast implant shell in a water bath and rubbing the sacrificial material from the breast implant shell. 
     
     
         20 . The method of  claim 14 , wherein the creating comprises forming the micrometer-scale pattern using a solid freeform fabrication (SFF) or layer manufacturing (LM) technique.