Porous surface layers with increased surface roughness and implants incorporating the same

Abstract

Systems and methods for providing tissue-interfacing surface layers with increased roughness can be attained by providing a metallic powder to a machined or previously machined tissue-interfacing surface of a porous foam structure. The metallic powder can have sizes and characteristics such that the porous structure can have an increased roughness at the tissue-interfacing machined surface while inhibiting the occlusion of the open pores in the porous metallic foam structure.

Description

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AI Technical Summary

Benefits of technology

This patent describes methods for improving the surface smoothness of porous structures such as metal foams without blocking their pores. One approach involves adding an asymmetric powder made up of small particles to the exterior of the structure after it has been shaped. Another technique involves applying multiple layers of this powder on top of each other before attaching them securely to the structure's surface. These improvements can be useful in applications where smoother surfaces would help reduce friction or improve fluid flow through the porous materials.

Problems solved by technology

The technical problem addressed in this patent is the need for an improved method for creating a porous metallic foam structure that allows for better bone ingrowth without sacrificing texture and pore size. The current methods require a secondary machining step to achieve the desired shape and dimensions, which can cause a loss of roughness on the machined surfaces. The patent seeks to address this problem by providing an improved method for maintaining the roughness of the tissue-engaging outer surfaces of the foam structure while increasing its porosity.

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