Material compositions, apparatus and method of manufacturing composites for medical implants or manufacturing of implant product, and products of the same

Abstract

A coated powder composite may include a core particle of Ca or an alloy thereof, or of Mg or an alloy thereof. One or more coating layers may be disposed about the core particle, cladding the core particle. The coated powder composite may be biodegradable.

1 - 73 . (canceled) 
     
     
         74 . A method of making a medical implant, the method comprising:
 providing a material composition, the material composition comprising coated powder composite; and   additive manufacturing the material composition into the medical implant.   
     
     
         75 . The method of  claim 74 , wherein the additive manufacturing comprises 3D printing the material composition into the medical implant. 
     
     
         76 . The method of  claim 75 , wherein the 3D printing comprises selective laser melting or electron beam melting. 
     
     
         77 . The method of  claim 74 , further comprising, prior to the additive manufacturing, forming a model of the medical implant, wherein the medical implant is additively manufactured based on the model. 
     
     
         78 . The method of  claim 77 , wherein the mode is a CAD model. 
     
     
         79 . The method of  claim 78 , wherein forming the model comprises scanning a portion of a patient, and forming the CAD model based on the scan. 
     
     
         80 . The method of  claim 79 , wherein the scanning comprises X-ray. 
     
     
         81 . The method of  claim 77 , further comprising hot isotactic pressing of the medical implant. 
     
     
         82 . The method of  claim 77 , further comprising subjecting the medical implant to heat treatment. 
     
     
         83 . The method of  claim 77 , further comprising subjecting the medical implant to a Hydrogen cleaning. 
     
     
         84 . The method of  claim 74 , wherein providing the material composition comprises depositing one or more coating layers onto core particles to form the coated powder composite. 
     
     
         85 . The method of  claim 84 , wherein the depositing comprises chemical vapor deposition. 
     
     
         86 . The method of  claim 84 , wherein the one or more coating layers comprise Mg or an alloy or oxide thereof, Sr or an alloy or oxide thereof, Ca or an alloy or oxide thereof, Zn or an alloy or oxide thereof, Si or an alloy or oxide thereof, Al or an alloy or oxide thereof, Fe or an alloy or oxide thereof, Ni or an alloy or oxide thereof, Ti or an alloy or oxide thereof, Cu or an alloy or oxide thereof, or Carbon. 
     
     
         87 . The method of  claim 84 , wherein the core particles comprise crushed bone. 
     
     
         88 . The method of  claim 84 , wherein the core particles comprise:
 a core particle comprising Mg or an alloy thereof with a first coating layer comprising Sr, a second coating layer comprising Ca, and a third coating layer comprising Si; or   a core particle comprising Mg or an alloy thereof with a first coating layer comprising Sr, a second coating layer comprising Ca, a third coating layer comprising Mg or an alloy thereof, a fourth coating layer comprising Zn or an alloy thereof, and a fifth coating layer comprising Si; or   a core particle comprising Ca or an alloy or oxide thereof or Mg or an oxide or alloy thereof; or   a core particle comprising Mg, first coating layer comprising Fe, and a second coating layer comprising Ca; or   a core particle comprising Mg with a first coating layer comprising Sr, and a second coating layer comprising Ca.   
     
     
         89 . The method of  claim 84 , wherein the one or more coating layers comprise a coating layer containing an alloy of Al and Zn having a weight ratio of Al to Zn of 3:1. 
     
     
         90 . The method of  claim 84 , wherein adjacent coating layers exhibit an electrical potential. 
     
     
         91 . The method of  claim 84 , wherein the core particles comprise Mg or an alloy or oxide thereof, or Ca or an alloy or oxide thereof, or Al or an alloy or oxide thereof; and
 wherein the one or more coating layers comprise an innermost coating layer comprising Fe, Mg, C, Cu; an outermost coating layer comprising C or Ti; and at least one intermediate coating layer positioned between the innermost coating layer and the outermost coating layer, the at least one intermediate coating layer comprising Al, Zn, Al 2 O 3 , Ca, Ti, C, or Sr.   
     
     
         92 . A method of making a medical implant, the method comprising:
 scanning a portion of a body, and forming a CAD model of a medical implant based on the scan;   providing a material composition, the material composition comprising coated powder composite; and   additive manufacturing the material composition into the medical implant. wherein the medical implant is additively manufactured based on the CAD model.   
     
     
         93 . A method of making a medical implant, the method comprising:
 scanning a portion of a body, and forming a CAD model of a medical implant based on the scan;   depositing, using chemical vapor deposition, one or more coating layers onto core particles to form a coated powder composite;   additive manufacturing the coated powder composite into the medical implant, wherein the medical implant is additively manufactured based on the CAD model.