Additive manufacturing of medical devices

Abstract

An example method for manufacturing an object is disclosed. The example method includes determining a material composition of a base material, where determining the material composition of the base material includes determining a relative percentage of a first metal and a relative percentage of a second metal that form the base material. The method also includes selecting a common laser processing wavelength to be used in processing the base material. The method also includes processing the base material with a laser to form a processed material, the laser emitting a laser beam during the processing of the base material that matches the common laser processing wavelength, and the material composition of the processed material being substantially similar to the material composition of the base material.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 117,778, filed November 24, 2020, entitled “Additive Manufacturing of Medical Devices,” the disclosure of which is incorporated herein by reference. Technical Field

[0003] This disclosure relates to medical devices and methods of manufacturing medical devices. More specifically, this disclosure relates to using a predetermined laser wavelength to control the materials chemistry of medical devices processed by additive manufacturing. Background Technology

[0004] Additive manufacturing (AM) is a method for improving the production of components for medical devices while reducing manufacturing costs and shortening timelines. Additive manufacturing is a process that uses computer-aided design (CAD) software and / or a 3D object scanner to guide hardware to deposit materials (such as metal powder) layer by layer in precise geometry.

[0005] Traditional manufacturing processes may involve removing material from a pre-formed structure through milling, machining, etching, or other methods to create medical devices. For example, the conventional manufacturing of medical stents can be accomplished by laser micro-cutting of a pre-formed metal tube. The laser cutting process removes selected material from the pre-formed tube, leaving a tubular component with the desired stent geometry. However, it is possible to improve traditional manufacturing techniques to achieve improved medical devices at a lower cost. For instance, 3D additive manufacturing (e.g., “3D printing,” “rapid prototyping”) techniques can be used to manufacture a variety of medical devices at a reduced cost while maintaining their superior performance.

[0006] As described above, additive manufacturing processes can deposit materials (e.g., metal powders) layer by layer to form a finished medical device. Furthermore, material deposition can be achieved via a laser that sintersulates the metal powders together before depositing another layer of powder onto a previously sintered metal layer. This process can be repeated automatically until the medical device is fully formed. This paper discloses an additive manufacturing process that optimizes the laser sintering process. Summary of the Invention

[0007] This disclosure provides designs, materials, manufacturing methods, and alternatives for using medical devices. An example method for manufacturing a medical device includes determining the material composition of a base material, wherein determining the material composition of the base material includes determining the relative percentages of a first metal and a second metal forming the base material. The method also includes selecting a common laser processing wavelength to be used in processing the base material. The method further includes processing the base material with a laser to form a processed material, wherein the laser emits a laser beam matched to the common laser processing wavelength during the processing of the base material, and the material composition of the processed material is substantially similar to that of the base material.

[0008] Optionally or additionally, the selection of a common laser processing wavelength to be used in the processing of the base material further includes analyzing the absorption wavelength spectrum of the first metal and the absorption wavelength spectrum of the second metal.

[0009] Optionally or additionally, the selection of a common laser processing wavelength to be used in the processing of the base material further includes comparing the absorption wavelength spectrum of the first metal and the absorption wavelength spectrum of the second metal to determine a common laser wavelength that does not excite the atoms of the first metal at a rate much higher than that of the atoms of the second metal.

[0010] Optionally or additionally, the first metal is nickel and the second metal is titanium.

[0011] Optionally or additionally, the laser wavelength is between 424nm and 425nm.

[0012] Optionally or additionally, the relative percentage of the first metal and the relative percentage of the second metal in the processed material differ by less than 0.15%.

[0013] Optionally or additionally, processing the base material with a laser to form the processed material includes laser sintering.

[0014] Optionally or additionally, processing the base material with a laser to form the processed material includes additive manufacturing.

[0015] Optionally or additionally, the method further includes treating the base material under a pressure between 2 ATM and 10 ATM, and wherein treating the base material under a pressure between 2 ATM and 10 ATM is designed to increase the vaporization temperature of the first metal and the second metal.

[0016] Optionally or additionally, the method further includes treating the base material under pressure between 1.5 ATM and 4 ATM, and wherein treating the base material under pressure between 1.5 ATM and 4 ATM is designed to limit the presence of one or more voids in the processed material.

[0017] Another method for manufacturing a metal substrate includes determining the material composition of a metal powder, wherein determining the material composition of the metal powder includes determining the relative percentage of a first metal and a second metal forming the metal powder. The method further includes determining a first wavelength spectrum of the first metal. The method also includes determining a second wavelength spectrum of the second metal. The method further includes comparing the first wavelength spectrum with the second wavelength spectrum to determine a common laser processing wavelength. The method further includes processing the metal powder with a laser to form the substrate, wherein the laser emits a laser beam matching the common laser processing wavelength during the processing of the metal powder, and wherein the material composition of the substrate is substantially similar to the material composition of the metal powder.

[0018] Optionally or additionally, the metal powder is processed with a laser at a common laser processing wavelength to form a scaffold without exciting multiple atoms of the first metal at a much higher rate than multiple atoms of the second metal.

[0019] Optionally or additionally, the laser wavelength is between 424 and 425 nm.

[0020] Optionally or additionally, the relative percentage of the first metal and the relative percentage of the second metal in the stent differ by less than 0.15%.

[0021] Optionally or additionally, processing metal powder with a laser to form the processed material includes laser sintering.

[0022] Optionally or additionally, processing metal powder with a laser to form the processed material includes additive manufacturing.

[0023] Optionally or additionally, the method further includes treating the metal powder under a pressure between 2 ATM and 10 ATM, and wherein treating the base material under a pressure between 2 ATM and 10 ATM is designed to increase the vaporization temperature of the first metal and the second metal.

[0024] Optionally or additionally, the method further includes treating the base material under pressure between 1.5 ATM and 4 ATM, and wherein treating the base material under pressure between 1.5 ATM and 4 ATM is designed to limit the presence of one or more voids in the processed material.

[0025] Example support includes a metal support formed of a metal alloy, wherein forming the metal support includes laser sintering a base powder to form the metal alloy, wherein the base powder is formed of a first metal and a second metal, and wherein laser sintering the base powder includes emitting a laser wavelength using a laser configured to excite a plurality of atoms of the first metal at a rate substantially equal to that of a plurality of atoms of the second metal.

[0026] Optionally or additionally, the first metal is nickel and the second metal is titanium.

[0027] The above summary of some embodiments is not intended to describe every disclosed embodiment or every implementation of this disclosure. The following drawings and detailed description illustrate these embodiments in more detail. Attached Figure Description

[0028] This disclosure can be more fully understood by taking into consideration the following detailed description in conjunction with the accompanying drawings, wherein:

[0029] Figure 1 This is an example bracket;

[0030] Figure 2 This is a flowchart of an example additive manufacturing process;

[0031] Figure 3 This is a flowchart of an example additive manufacturing process.

[0032] While this disclosure may be modified and alternatively implemented in various ways, its details have been shown by way of example in the accompanying drawings and will be described in detail. However, it should be understood that this disclosure is not intended to limit it to the specific embodiments described. Rather, it is intended to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of this disclosure. Detailed Implementation

[0033] The terms defined below shall be used as defined hereunless otherwise specified in the claims or elsewhere in this specification.

[0034] This document assumes that all numerical values ​​are modified by the term "about," whether explicitly stated or not. The term "about" generally refers to a range of numbers that a person skilled in the art would consider equivalent to the listed values ​​(e.g., having the same function or result). In many cases, the term "about" may include numbers rounded to the nearest significant figure.

[0035] The representation of the endpoint numerical range includes all numbers in that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).

[0036] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural objects, unless otherwise expressly stated. As used in this specification and the appended claims, the term “or” is generally used in its sense that it includes “and / or,” unless otherwise expressly stated.

[0037] It should be noted that when the specification refers to "one embodiment," "some embodiments," "other embodiments," etc., it means that the described embodiment may include one or more specific features, structures, and / or characteristics. However, such a description does not necessarily mean that all embodiments include that specific feature, structure, and / or characteristic. Furthermore, when a specific feature, structure, and / or characteristic is described in conjunction with an embodiment, it should be understood that, whether explicitly described or not, these features, structures, and / or characteristics may also be used in conjunction with other embodiments, unless otherwise expressly stated to the contrary.

[0038] The following detailed description should be read in conjunction with the accompanying drawings, in which similar elements are numbered the same. The drawings, which are not necessarily drawn to scale, depict illustrative embodiments and are not intended to limit the scope of this disclosure.

[0039] Furthermore, although the additive material processing techniques described herein may be specifically discussed with reference to endovascular stents in the particular embodiments described herein, this disclosure is applicable to a wide variety of medical devices. For example, this disclosure is applicable to heart valve replacement devices and components thereof, self-expanding stents, balloon-expandable stents, occlusion devices, cardiovascular filters (e.g., IVC filters), fixation devices, guidewires, various catheters (e.g., balloons, stent delivery, etc.), drive shafts of rotating devices (e.g., rotational ablative catheters and IVUS catheters), endoscopic devices, laparoscopic devices, embolization protection devices, sensors, spinal or cranial navigation devices, implantable leads, implantable monitors, active implants, bone fixation hardware, cochlear implants, and other such devices.

[0040] Additionally, while some embodiments may be suitable or configured for use within a patient's vascular system, others may be suitable and / or configured for other anatomical structures. It should be understood that a variety of materials, sizes, and structures can be used to construct suitable embodiments, depending on the desired characteristics. The following examples of some embodiments are included by way of example only and are not intended to be limiting. Furthermore, medical devices formed by the additive manufacturing processes described herein may comprise one or more materials exhibiting shape memory properties, superelastic properties, or both. These materials may be metallic alloys, such as…

[0041] Typically, some nickel-titanium (Ni-Ti) alloys can exhibit shape memory or hyperelastic (or pseudoelastic) properties, or both. Although Essentially a binary alloy of nickel and titanium, some superelastic and / or shape-memory Ni:Ti alloys may contain other elements, such as cobalt or vanadium. Furthermore, some other alloys exhibit shape-memory or superelastic properties, or, like some Ni:Ti alloys, possess both shape-memory and superelasticity. Some examples of these alloys are: AgCd, AuCd, AuCu, CuAlNi, CuAuZn, CuSn, CuZn, CuZnSi, CuZnSn, CuZnAl, CuZnGa, CuZnXe, CuAlNi, InTl, NiAl, FePt, FePd, FeMn, Fe3Be, Fe3Pt, FeNiTiCo, and MnCu.

[0042] Hyperelasticity and shape memory are two distinct manifestations of reversible phase transformation. Hyperelasticity can be defined as the nonlinear recoverable deformation behavior of Ni-Ti shape memory alloys at temperatures above the austenite completion temperature (Af). This nonlinear deformation arises from stress-induced martensite formation under loading, which spontaneously reverts to austenite upon unloading. Shape memory alloys can be defined as metals that, after significant plastic deformation in the martensitic phase, undergo thermoelastic changes in their crystal structure upon heating through their transformation temperature range, resulting in deformation recovery. The unique crystal structure of Ni-Ti alloys can lead to different responses to additive manufacturing technologies, as described below.

[0043] Figure 1 An exemplary support 10 is illustrated. The support 10 may include one or more support pillar members 16 extending from a first end region 12 to a second end region 14. The support pillar members 16 may extend longitudinally along the support 10. Although Figure 1 The support strut member 16 extends along the entire length of the support 10, but in other examples, the support strut member 16 may extend only along a portion of the support 10.

[0044] In some cases, stent 10 may be a self-expanding stent or a balloon-expandable stent. Examples of self-expanding stents may include stents having one or more struts 16 that are combined together to form a rigid and / or semi-rigid stent structure. For example, stent 10 may be a rigid or semi-rigid structure formed by an additive manufacturing process (e.g., 3D laser printing). Openings or gaps through the walls of stent 10 may be defined between adjacent stent struts 16.

[0045] The stent 10 in the examples disclosed herein can be made of a variety of materials. For example, the stent 10 (e.g., self-expanding or balloon-expanding) can be made of metal (e.g., or include Other metal alloys may be used. In other cases, the scaffold 10 may be made of polymeric materials (e.g., PET). In still other cases, the scaffold 10 may be made of a combination of metals and polymeric materials. Additionally, the scaffold 10 may include bioabsorbable and / or biodegradable materials.

[0046] During use, the stent 10 can expand from an initial small diameter to a larger diameter, allowing the stent 10 to contact the blood vessel wall and thus keep the blood vessel open. The stent strut 16 provides flexibility and conformability to the stent 10, enabling the stent 10 to adapt to the contour of the blood vessel.

[0047] The stent 10 may include (e.g., formed therefrom) a biocompatible alloy composition capable of providing the stent 10 with a complementary combination of physical and mechanical properties that enhance its performance. For example, the alloy composition may include relatively dense elements that enhance the radiopaqueness of the stent 10. Therefore, the stent 10 can be readily detected during X-ray fluoroscopy and CT scans. The alloy composition may also include elements with low magnetic susceptibility. Therefore, the stent 10 is compatible with MRI techniques.

[0048] Meanwhile, the metal alloy used to form the stent 10 may have mechanical properties that allow it to be manipulated within the stent delivery system and provide good mechanical performance characteristics to the device. For example, the alloy composition may have stiffness or elastic modulus to provide reduced recoil to the stent 10, for example, when the stent is coiled on the delivery catheter or when the stent expands against the vessel wall.

[0049] Figure 2 An example flow chart 100 is illustrated for manufacturing an example medical device using an additive manufacturing process. For example, Figure 2 The flowchart 100 shown can be used for manufacturing Figure 1 The medical stent 10 is shown. However, as discussed above, Figure 2 The example flowchart 100 shown can be used to form a variety of medical devices (some of which have been disclosed above) and is not limited to these. Figure 1 The bracket 10 shown.

[0050] Figure 2An example first step in the additive manufacturing process shown may include obtaining raw material 102 from which a final processed object / part (e.g., a medical device) may be formed. It is understood that the raw material used in additive manufacturing process 100 may include raw metal powder. The raw metal powder may be formed from two or more metals and is therefore commonly referred to as a metal alloy powder. It is understood that the raw metal powder may include two or more metals that may exist in different (relative) proportions in the raw metal powder. For example, the raw metal powder used in additive manufacturing step 102 may include nickel and titanium (e.g., Ni-Ti alloy powder), whereby nickel and titanium exist in different relative proportions in the raw metal powder.

[0051] In some additive manufacturing processes, it may be desirable to obtain a raw nickel-titanium alloy powder with relatively equal percentages of nickel and titanium. In other words, in some additive manufacturing process technologies, it may be desirable to begin the manufacturing process with a Ni-Ti alloy powder having approximately 50% nickel and 50% titanium. However, this is not intended to be limiting. It should be understood that the additive manufacturing techniques used herein are applicable to a wide variety of different metal alloys, some of which may include alternative compositions to Ni-Ti alloys.

[0052] After selecting the raw material metal powder to be used in the manufacturing process, an exemplary next step may include determining 104 (e.g., confirming) the basic elements (e.g., metals) present in the metal powder. In some instances, the relative percentage of each basic element (e.g., metal) present in the raw material powder may be determined in step 104.

[0053] One technique that can be used to determine the basic elements present in raw materials may include chemical composition testing of the raw material metal powder. In addition to determining the relative percentage of each basic metal and chemical present, chemical composition testing can also determine which basic metals and chemicals are present in the original sample.

[0054] As described above, additive manufacturing processes may also include using a laser (e.g., a laser printer or similar device) to sinter raw metal powder layer by layer into a finished part (e.g., a finished medical device) via a 3D laser printing process. Typically, the laser sintering process may involve applying a laser beam having a wavelength (in nanometers) and power (in watts) to a bed of raw metal powder. In some cases, the laser beam may be applied to the raw metal powder within an inert gas pressurized chamber. It is understood that the energy applied by the laser can be strong enough to allow the metal powder to melt and form a solid metal. This laser process is repeated layer by layer until the finished part is completed, whereby each new layer is fused to the previous one.

[0055] In some cases, applying energy via a laser beam can excite the atoms of one base material to a higher degree than that of another. For example, applying a laser beam with a specific wavelength and power to a Ni-Ti alloy can excite nickel atoms at a higher rate than titanium atoms. This uneven energy absorption between nickel and titanium atoms can result in a higher level of nickel atom vaporization compared to titanium atoms (e.g., uneven heating). Furthermore, it is understood that unequal vaporization rates of nickel atoms relative to titanium atoms, compared to the initial percentages of nickel and titanium atoms in the base metal powder (e.g., raw material powder), can result in the final processed medical device having a different percentage of nickel atoms than titanium atoms.

[0056] For example, as mentioned above, the initial base metal powder may comprise approximately 54% nickel and 46% titanium in relative percentages of nickel and titanium atoms. However, after processing the metal powder at a specific wavelength and power, the final processed component (e.g., a medical device) may have a relative percentage of nickel and titanium atoms of, for example, 51% nickel and 49% titanium.

[0057] It is also understood that altering the relative percentages of nickel and titanium atoms during the processing steps can directly affect the performance of the final processed part. For example, the exemplary support 10 described above can be designed to exhibit a specific Ni-Ti transition temperature corresponding to a 54 / 46 ratio of nickel to titanium atoms. Therefore, changing the ratio of nickel to titanium atoms to a ratio other than 54 / 46 (e.g., a ratio of 51 / 49) can result in the support 10 having a transition temperature different from the bulk performance of the support 10 (and thus potentially less desirable). Therefore, it may be desirable to minimize the non-uniform vaporization of nickel and titanium atoms during the laser processing methods described herein.

[0058] An example method for minimizing the non-uniform vaporization of nickel atoms relative to titanium atoms during laser processing of Ni-Ti alloys may include applying laser energy at a wavelength that does not excite atoms of another base element (e.g., nickel) at a higher rate than that of a base element (e.g., titanium). Figure 2 Step 106 of the additive manufacturing process illustrated illustrates a method for selecting a “common” wavelength for two base elements (e.g., nickel and titanium) such that applying laser energy at this common wavelength does not excite atoms of the other base element (e.g., nickel) at a higher rate than one base element (e.g., titanium).

[0059] Determining a common wavelength for two base elements (e.g., nickel and titanium) so that applying laser energy at this common wavelength will not excite atoms of the other base element (e.g., nickel) at a higher rate than that of the first base element (e.g., nickel) can include comparing the emission and absorption spectra of each base element (e.g., nickel and titanium) to determine a common wavelength at which neither target base element (e.g., nickel and titanium) absorbs light. Examples of common wavelengths at which neither nickel nor titanium readily absorbs light (determined by comparing the emission and absorption spectra of nickel and titanium) could include wavelengths of about 400–600 nm, or about 495–570 nm, or about 424.68 + / - 0.05 nm.

[0060] In another exemplary method, minimizing the non-uniform vaporization of nickel atoms relative to titanium atoms during laser processing of Ni-Ti alloys may involve applying laser energy at a wavelength targeted to the absorption spectrum of an element having a relatively high melting point compared to an element having a relatively low melting point. However, when analyzing the absorption spectrum of an element with a higher melting point, a wavelength that does not interact with the absorption spectrum of the lower melting point element may be selected. For example, a wavelength at which elements with higher melting points (e.g., titanium) readily absorb light while elements with relatively lower melting points (e.g., nickel) do not absorb light may include a wavelength of 659 nm ± 1.0 nm.

[0061] It is understood that after identifying the common wavelength of each base element (e.g., nickel and titanium) using the emission and absorption spectra of each base element, the laser parameters can be adjusted so that the laser emits its laser beam at a predetermined common wavelength when processing the raw metal powder (as described above). It is also understood that processing the raw metal powder at the predetermined common wavelength will result in uniform heating of the target base metal (e.g., the base material whose emission and absorption spectra are compared). During laser sintering, the uniform heating (and melting) of the base metal in the raw powder can result in a finished component that includes a net change in the atomic ratio of the base metal between the raw metal powder and the finished part that is substantially zero (e.g., a zero net change in the ratio of nickel atoms to titanium atoms).

[0062] Figure 2 The illustration shows that the final step of additive manufacturing process 100 may include analyzing the finished part to ensure that the net change in the proportion of the base metal atoms between the raw metal powder and the finished part is substantially zero (e.g., the net change in the proportion of nickel atoms to titanium atoms is zero). Zero net change in the proportion of the individual base metal atoms ensures that the performance characteristics of the finished part (e.g., a medical device such as the stent 10 described above) remain unchanged from the raw metal powder to the finished part.

[0063] Figure 3 Another example additive manufacturing process 200 is illustrated. Additive manufacturing process 200 may share several steps with the additive manufacturing process 100 described above. For example, Figure 2 The steps shown in the middle frames 202, 204, 206, 208, and 210 are essentially similar to those described above. Figure 1 The disclosure described in steps 102, 104, 106 and 110.

[0064] However, Figure 3 As shown, in some examples, additive manufacturing process 200 may include an additional step 207, under which a pre-selected pressure is chosen at which a laser beam (having a pre-selected common wavelength, as described above) can be applied during processing 208 of the raw metal powder. It is understood that the laser sintering process (as described above) can be performed within a pressurized chamber, thereby allowing control over the pressure at which the laser beam can be applied.

[0065] It is also understood that pressurizing the gas environment in the laser chamber during the laser sintering process can increase the vaporization temperature of each base metal element in the raw metal powder. Furthermore, the vaporization temperature of each base metal element can be increased to a level much higher than the melting point of each base element (and also much higher than what is applicable to conventional lasers), thereby ensuring that proper melting occurs during sintering and that there is no preferential vaporization, thus preventing uneven loss of base element atoms in this processing step.

[0066] In some examples, the laser chamber gas environment can be pressurized to a range of approximately 2 ATM to 10 ATM. In still other examples, the laser chamber gas environment can be pressurized to a range of approximately 1.5 ATM to 4 ATM, which can be considered relatively low pressure compared to the relatively high pressures of laser processing as described above. Performing laser sintering processes at relatively low pressures (e.g., between 1.5 ATM and 4 ATM) can significantly reduce (or eliminate) voids formed in the finished parts. In other words, performing laser sintering processes at these relatively low pressures can compress and remove bubbles (e.g., voids) that might otherwise form in the finished product.

[0067] It should be noted that while the above discussion focuses primarily on the properties of laser-processed Ni-Ti alloys and related alloys, the same analysis can be applied to alloys containing any other base metal element. In other words, the same processing techniques, including comparing emission and absorption spectra to find common wavelengths and increasing pressure during laser sintering, can be applied to alloys with any base metal element.

[0068] It should be understood that this disclosure is illustrative in many respects only. Changes in detail may be made, particularly in terms of shape, size, and arrangement of steps, without departing from the scope of this disclosure. To the extent appropriate, this may include any feature of an exemplary embodiment used in other embodiments. Of course, the scope of this disclosure is defined by the language of the appended claims.

Claims

1. A method for manufacturing a medical device, the method comprising: Determine the material composition of the base material, wherein the base material comprises a first percentage of a first metal and a second percentage of a second metal; Select a laser processing wavelength common to both the first metal and the second metal; The base material is processed using a laser to form a first layer of processed material, wherein the laser emits a laser beam that matches a laser processing wavelength common to both the first metal and the second metal during the processing of the base material; An additional base material is placed on the first layer of processed material; The additional base material disposed on the first layer of processed material is processed to form a second layer of processed material, which is fused with the first layer of processed material, wherein the fused first layer of processed material and the second layer of processed material form at least a portion of the medical device; The base material is processed using a laser processing wavelength common to both the first metal and the second metal to form the medical device, thereby minimizing the non-uniform vaporization of the first metal relative to the second metal.

2. The method as described in claim 1, wherein, Selecting a laser processing wavelength common to both the first metal and the second metal for processing the base material also includes analyzing the absorption wavelength spectrum of the first metal and the absorption wavelength spectrum of the second metal.

3. The method as described in claim 2, wherein, Selecting a laser processing wavelength common to both the first metal and the second metal for processing the base material further includes comparing the absorption wavelength spectra of the first metal and the second metal to determine a laser processing wavelength common to both the first metal and the second metal, the laser processing wavelength minimizing the non-uniform vaporization of the first metal relative to the second metal.

4. The method of claim 3, wherein the first metal is nickel and the second metal is titanium.

5. The method of claim 3, wherein the laser processing wavelength shared by the first metal and the second metal is between 424 nm and 425 nm.

6. The method of any one of claims 1-5, wherein the relative percentage of the first metal and the relative percentage of the second metal in the processed material differ by less than 0.15%.

7. The method of any one of claims 1-5, wherein processing the base material with a laser to form the processed material comprises laser sintering.

8. The method of any one of claims 1-5, wherein processing the base material with a laser to form the processed material comprises additive manufacturing.

9. The method of any one of claims 1-5, wherein the method further comprises processing the base material under a pressure between 2 ATM and 10 ATM, and wherein processing the base material under a pressure between 2 ATM and 10 ATM is designed to increase the vaporization temperature of the first metal and the second metal.

10. The method of any one of claims 1-5, wherein the method further comprises processing the base material under a pressure between 1.5 ATM and 4 ATM, and wherein processing the base material under a pressure between 1.5 ATM and 4 ATM is designed to limit the presence of one or more voids in the processed material.

11. A method for manufacturing a metal support, the method comprising: Determining the material composition of a metal powder, wherein determining the material composition of the metal powder includes determining the relative percentage of a first metal and a second metal forming the metal powder; Determine the first wavelength spectrum of the first metal; Determine the second wavelength spectrum of the second metal; Compare the first wavelength spectrum with the second wavelength spectrum to determine the laser processing wavelength common to both the first metal and the second metal; and The metal powder is processed with a laser to form the support, wherein the laser emits a laser beam that matches a laser processing wavelength common to both the first metal and the second metal during the processing of the metal powder, and wherein processing the metal powder with a laser processing wavelength common to both the first metal and the second metal to form the support minimizes the non-uniform vaporization of the first metal relative to the second metal.

12. The method of claim 11, wherein the laser processing wavelength common to both the first metal and the second metal is between 424 and 425 nm.

13. The method of claim 12, wherein the relative percentage of the first metal and the relative percentage of the second metal in the support differ by less than 0.15%.

14. The method of claim 13, wherein processing the metal powder with a laser to form the processed material includes laser sintering.

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