Three-dimensional porous structures for bone ingrowth and methods of manufacture - Patents.com

Abstract

An orthopedic prosthetic component is provided. The orthopedic prosthetic component includes a porous three-dimensional structure (100) shaped to be implanted within a patient's body. The porous three-dimensional structure includes a plurality of unit cells (400). At least one unit cell includes a first geometric structure having a first geometric shape and including a plurality of first struts (410), and a second geometric structure having a second geometric shape and including a plurality of second struts (420) connected to some of the plurality of first struts to form a second geometric structure.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This claims priority to U.S. Patent Application No. 62 / 906,004, filed September 25, 2019, the disclosure of which is incorporated by reference herein as if set forth in its entirety.

[0002] FIELD OF THEINVENTION Embodiments disclosed herein are directed generally to porous metal structures and methods for their manufacture, and more specifically to porous metal structures in medical devices having a geometric lattice configuration suitable for enabling precise control of porosity and pore size in the porous metal structures. [Background technology]

[0003] SUMMARY OF THE DISCLOSURE The embodiments disclosed herein are generally directed to three-dimensional porous structures for bone ingrowth and methods for manufacturing same.

[0004] The field of rapid prototyping and additive manufacturing has seen many advancements over the years, particularly for rapid prototyping of articles such as prototype parts and mold dies. These advancements have reduced manufacturing costs and time while improving the accuracy of the final product compared to traditional machining processes, such as those in which a material (e.g., metal) begins as a block of material and is then machined into the final product.

[0005] However, the main focus of rapid prototyping three-dimensional structures has been to increase the density of the rapid prototyping structures. Examples of modern rapid prototyping / additive manufacturing techniques include sheet lamination, adhesive bonding, laser sintering (or selective laser sintering), laser melting (or selective laser sintering), photopolymerization, droplet deposition, stereolithography, 3D printing, fused deposition modeling, and 3D plotting. In particular, in the fields of selective laser sintering, selective laser melting, and 3D printing, improvements in the production of high-density parts have made these techniques useful for designing and precisely manufacturing articles such as high-density metal parts.

[0006] In the past few years, some in the additive manufacturing field have attempted to create solutions that provide the mechanical strength, interconnected channel design, porosity, and pore size in porous structures required for applications that promote mammalian cell growth and regeneration. However, current methods and geometries have limited control over pore size distribution, which strongly influences mammalian cell ingrowth behavior, such as bone. Furthermore, current methods and geometries often fall short in producing porous structures with unit cell geometries that simultaneously have pore sizes and porosities in the range considered beneficial for ingrowth, while maintaining structural integrity during the manufacturing process (e.g., 3D printing). As a result, current unit cell geometries must have either very large pore sizes or very low porosities. Furthermore, current methods and geometries generally prevent a close correlation between the strut lengths and unit cell diameters selected within the structure geometry and the resulting geometric characteristics desired for the porous structure.

[0007] Current methods for producing porous metal materials for bone ingrowth have limited control over the pore size distribution, which has a strong effect on bone ingrowth behavior. Better bone ingrowth would be possible if maximum pore size, minimum pore size, and porosity could be simultaneously better controlled. Additive manufacturing techniques conceptually allow for the production of lattice structures with full control over the geometry, but in practice are limited by the smallest strut outer diameter the machine can build and by the need for any lattice structure to be self-supporting. The minimum strut diameter for current 3D printers is around 200-250 microns, which means that many geometric structures must have either very large pore sizes or very low porosity. Summary of the Invention [Means for solving the problem]

[0008] According to one aspect of the disclosure, an implantable device includes a porous three-dimensional structure shaped to be implanted in a patient's body. The porous three-dimensional structure includes a plurality of interconnected organic unit cells. Each organic unit cell includes a plurality of outer struts and a plurality of inner struts. Respective groups of three outer struts intersect to define a respective plurality of outer nodes. Each inner strut extends from a different respective one of the outer nodes, and the inner struts intersect to define an inner node. The plurality of outer nodes includes a first outer node defined by an intersection of a first group of three outer struts and a second outer node defined by an intersection of a second group of three outer struts. A shortest path from the first outer node to the second outer node along the struts includes only the three intermediate outer nodes of the plurality of outer nodes. A straight imaginary line extends through the first outer node and the second outer node, and the inner node is offset from the straight imaginary line.

[0009] In one embodiment, each of the outer struts has a constant thickness along its entire length.

[0010] In another embodiment, each of the inner struts has a constant thickness along its entire length.

[0011] In another embodiment, at least one of the outer struts is curved along its length.

[0012] In another embodiment, at least one of the inner struts is curved along its length.

[0013] In another embodiment, all of the outer struts extend along their respective lengths from and to their respective pairs of outer nodes, and the lengths of at least some of the outer struts differ from one another.

[0014] In another embodiment, at least one of the outer struts is curved.

[0015] In another embodiment, all of the outer struts are substantially straight along their entire respective lengths.

[0016] In another embodiment, the plurality of outer struts includes a longest outer strut and a shortest outer strut, the length of the shortest outer strut being greater than or equal to about 60% of the length of the longest outer strut.

[0017] In another embodiment, the plurality of outer struts includes a longest outer strut and a shortest outer strut, the length of the shortest outer strut being greater than or equal to about 1 / 3 of the length of the longest outer strut.

[0018] In another embodiment, at least one of the inner struts is curved.

[0019] In another embodiment, all of the inner struts are substantially straight along their entire respective lengths.

[0020] In another embodiment, the implantable device has a porosity between about 50% and about 75%.

[0021] In another embodiment, an implantable device includes a number of pores each defined by a unit cell, and less than 14.3 percent of the pores have a pore size less than 0.1 mm.

[0022] Fifty percent of the pores have a pore size in the range of about 0.2 mm to about 0.7 mm.

[0023] In another embodiment, the outer struts cooperate to define a number of outer openings and the inner struts cooperate with the number of outer struts to form a number of inner openings, the porous three-dimensional structure defines window sizes defined as diameters of circles positioned within corresponding outer and inner openings such that each of the struts defining the outer and inner openings are positioned on a tangent to the circle, the implantable device includes a number of pores each defined by a unit cell, the pores defining a ratio of their respective pore size to any of its window sizes that is in the range of 1.00 to 2.90.

[0024] In another embodiment, the inner node is the only inner node of the porous three-dimensional structure that is internal to the outer nodes.

[0025] In another embodiment, all of the inner struts intersect at an inner node.

[0026] In another embodiment, the implantable device includes an organic rhombohedral spheroid having greater ductility than a corresponding geometric rhombohedral spheroid.

[0027] In another embodiment, each organic unit cell defines a first half and a second half separated from the first half by a plane that bisects the organic unit cell structure, and for all orientations of the plane, 1) at least some of the outer nodes of the first half of the organic unit cell structure are reoriented in a first orientation relative to corresponding outer nodes of the corresponding geometric unit cell structure, and 2) at least some of the outer nodes of the second half of the organic unit cell structure are reoriented in a second orientation, different from the first orientation, relative to corresponding outer nodes of the corresponding geometric unit cell structure.

[0028] In another embodiment, an orthopedic implant comprises a porous three-dimensional structure and a solid base, the porous three-dimensional structure attached to the solid base.

[0029] According to another aspect of the present disclosure, an implantable device includes a porous three-dimensional structure shaped to be implanted within a patient's body. The porous three-dimensional structure includes a plurality of interconnected organic unit cell structures. Each organic unit cell structure includes a plurality of outer struts. At least three of the plurality of outer struts intersect to define a respective plurality of outer nodes. The outer struts and nodes combine to substantially define a geometric structure within 50% of a geometric rhombic dodecahedron. The outer struts have a constant thickness along their entire respective lengths. The outer nodes include a first outer node and a second outer node opposite the first outer node to define a first pair of opposing nodes. The outer nodes further include a third outer node and a fourth outer node opposite the third outer node to define a second pair of opposing nodes. The outer nodes further include a fifth outer node and a sixth outer node opposite the fifth outer node to define a third pair of opposite nodes. All the opposite outer nodes are separated from each other by three intermediate outer nodes of the plurality of outer nodes along the shortest path along the outer strut. A first straight imaginary line extends through the first outer node and the second outer node, a second straight imaginary line extends from the third outer node to the fourth outer node, and a third straight imaginary line extends from the fifth outer node to the sixth outer node. The first straight imaginary line and the second straight imaginary line intersect each other at a first intersection point with respect to the selected field of view of the porous three-dimensional structure, and the third straight imaginary line intersects with the first straight imaginary line at a respective second intersection point offset from the first intersection point with respect to the selected field of view of the porous three-dimensional structure.

[0030] In one embodiment, each of the organic unit cell structures defines a first half and a second half separated from the first half by a plane that bisects the organic unit cell structure, and for all orientations of the plane, 1) at least some of the outer nodes of the first half of the organic unit cell structure are reoriented in a first orientation relative to the corresponding outer nodes of the corresponding geometric unit cell structure, and 2) at least some of the outer nodes of the second half of the organic unit cell structure are reoriented in a second orientation, different from the first orientation, relative to the corresponding outer nodes of the corresponding geometric unit cell structure.

[0031] In another embodiment, the outer struts define a first geometric structure and the porous three-dimensional structure further includes a plurality of inner struts that combine with the outer struts to define a plurality of second geometric structures within the first geometric structure.

[0032] In another embodiment, the plurality of medial struts comprises four medial struts that cross each other to define a medial node.

[0033] In another embodiment, the plurality of inner struts comprises eight inner struts, and all of the plurality of inner struts intersect with at least one other of the inner struts.

[0034] In another embodiment, the implantable device includes an organic rhombic dodecahedron that has greater ductility than a corresponding geometric rhombic dodecahedron.

[0035] According to yet another aspect of the present disclosure, an implantable device includes a porous three-dimensional structure shaped to be implanted within a patient's body. The porous three-dimensional structure includes a plurality of interconnected unit cells. Each unit cell includes a plurality of struts. At least three struts of the plurality of struts intersect to define a respective plurality of nodes, and at least one of the struts of the plurality of struts is curved along its length between a first node of the plurality of nodes and a second node of the plurality of nodes.

[0036] In one embodiment, the struts define groups of three struts that intersect with one another to define a first node and a second node.

[0037] According to another aspect, a porous three-dimensional structure is shaped to be implanted within a patient's body. The porous three-dimensional structure includes a plurality of interconnected unit cells. Each unit cell includes a plurality of struts. At least three struts of the plurality of struts intersect to define a respective plurality of nodes, and at least one of the struts of the plurality of struts is curved along its length between a first node of the plurality of nodes and a second node of the plurality of nodes.

[0038] In another embodiment, an orthopedic implant comprises a porous three-dimensional structure and a solid base, the porous three-dimensional structure attached to the solid base. [Brief description of the drawings]

[0039] For a more complete understanding of the principles disclosed herein and their advantages, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: [Figure 1] FIG. 1 is a simplified elevational view of an orthopedic prosthetic component. [Diagram 2] FIG. 2 is a simplified perspective view of the orthopedic prosthetic component of FIG. 1. [Diagram 3] FIG. 3 is a perspective view of a unit cell of the porous structure of the orthopedic prosthetic component of FIGS. 1 and 2. [Figure 4] FIG. 4 is a perspective view of one geometric structure of the unit cell of FIG. [Diagram 5] FIG. 4 is a simplified perspective view of an alternative geometric configuration of the unit cell of FIG. [Figure 6] FIG. 3 is a perspective view of another embodiment of a unit cell of the porous structure of the orthopedic prosthetic component of FIGS. 1 and 2. [Figure 7] FIG. 4 is a simplified perspective view of an alternative geometric configuration of the unit cell of FIG. [Figure 8] 1 is a chart of porosity (percent) versus strut length / diameter for various unit cell geometries according to various embodiments. [Figure 9] 1 is a chart of pore size and minimum pore window opening size versus porosity (percent) for various unit cell geometries, according to various embodiments. [Figure 10] FIG. 1 illustrates the association of window size to unit cell structure according to various embodiments. [Figure 11] FIG. 1 illustrates a workflow for fabricating a porous three-dimensional structure, according to various embodiments. [Figure 12A] FIG. 5 is another perspective view of the geometric structure of the unit cell of FIG. [Figure 12B] FIG. 12B is a perspective view of an organic structure modified by 25% relative to the geometric structure shown in FIG. 12A. [Figure 12C] FIG. 12B is a perspective view of an organic structure that is 50% modified relative to the geometric structure shown in FIG. 12A. [Figure 13A] FIG. 4 is another perspective view of the geometric structure of the unit cell of FIG. [Figure 13B] FIG. 13B is a perspective view of an organic structure modified by 25% relative to the geometric structure shown in FIG. 13A, showing straight and curved outer struts. [Figure 13C] FIG. 13C is a perspective view of the organic structure of FIG. 13B showing the outer struts, all of which are straight. [Figure 13D] FIG. 13B is a perspective view of an organic structure modified 50% relative to the geometric structure shown in FIG. 13A showing straight and curved outer struts. [Figure 13E] FIG. 13E is a perspective view of the organic structure of FIG. 13D showing the outer struts, all of which are straight. [Figure 14] FIG. 13D is a chart plotting the percentage of pores as a function of pore size for a porous three-dimensional structure having the unit cell geometry shown in FIG. 13C and having a porosity of about 55%. [Figure 15] FIG. 13D is a chart plotting the percentage of pores as a function of pore size for a porous three-dimensional structure having the unit cell geometry shown in FIG. 13C and having a porosity of about 65%. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] This specification describes exemplary embodiments and applications of the present disclosure. However, this disclosure is not limited to these exemplary embodiments and applications, nor is it limited to the manner in which the exemplary embodiments and applications operate or are described herein. Furthermore, the figures may show simplified or partial views, and the dimensions of the elements in the figures may be exaggerated or otherwise not to scale. Furthermore, when the terms "on," "attached to," "connected to," "coupled to," or similar phrases are used herein, an element (e.g., a material, layer, base, etc.) can be "on," "attached to," "connected to," or "coupled to" another element, regardless of whether the element is directly on, attached to, connected to, or coupled to the other element, or whether one or more intervening elements are between one element and the other element, or whether the two elements are integrated into a single piece. Also, unless the context dictates otherwise, when provided, directions (e.g., above, below, top, bottom, side, up, down, under, over, upper, lower, horizontal, vertical, "x", "y", "z", etc.) are also relative and are provided by way of example only for ease of description and discussion and not for purposes of limitation. Furthermore, when referring to a list of elements (e.g., elements a, b, c), such reference is intended to include any one of the listed elements by itself, any combination of less than all of the listed elements, and / or combinations of all of the listed elements. The division of chapters herein is merely for ease of review and does not limit any combination of the elements described.

[0041] As used herein, "bonded to" or "bonding" refers to the attachment of a metal to a metal by a variety of physicochemical mechanisms, including but not limited to metallic bonding, electrostatic attraction, and / or adhesive forces.

[0042] Unless otherwise defined, scientific and technical terms used in connection with the teachings described herein shall have the meanings that are commonly understood by those of ordinary skill in the art.

[0043] The present disclosure relates to porous three-dimensional metal structures and methods for their manufacture for medical applications. As described in more detail below, the porous metal structures promote hard or soft tissue interlocking between a prosthetic component implanted in a patient's body and the patient's surrounding hard or soft tissue. For example, when included in an orthopedic prosthetic component configured to be implanted in a patient's body, the porous three-dimensional metal structures can be used to provide a porous outer layer of the orthopedic prosthetic component to form a bone ingrowth structure. Alternatively, the porous three-dimensional metal structures can be used as implants with the necessary structural integrity to both achieve the intended function of the implant and provide interconnected porosity for tissue interlocking with surrounding tissues (e.g., bone ingrowth). In various embodiments, the types of metals that can be used to form the porous three-dimensional metal structures can include, but are not limited to, titanium, titanium alloys, stainless steel, cobalt chromium alloys, tantalum, or niobium.

[0044] 1 and 2, an implantable device such as an orthopedic implant or prosthetic component 100 is shown. The prosthetic component 100 includes a base 110, a porous three-dimensional structure or layer 120, and a pyramid or stem 130 extending away from the base 110. In an exemplary embodiment, the porous structure 120 surrounds a portion of the base 110 and a portion of the stem 130. It should be understood that the porous structure 120 may be provided as a layer separate from the base 110 and / or the stem 130. The porous structure 120 may also be provided as a coating surrounding all of the base 110 and / or the stem 130. As described in more detail below, the porous structure includes a plurality of unit cells that define voids or spaces that allow for bone ingrowth, thereby facilitating fixation of the prosthetic component 100 to the patient's bone.

[0045] The orthopaedic implant 100 may be implanted in the tibia. For example, the stem 130 may be inserted into the tibia with the ledge portion 140 of the implant 100 seated against the proximal portion of the tibia. It should be understood that the various porous structures described herein may be incorporated into a variety of orthopaedic implant designs, including, for example, tibial or femoral prosthetic components similar to the tibial and femoral components shown in U.S. Patent No. 8,470,047, which are expressly incorporated herein by reference. The porous structures may also be included in other orthopaedic implant designs, including femoral prosthetic components and patellar components shaped to engage prosthetic components for use in hip or shoulder arthroplasty.

[0046] It is noted above and below that the base 110 can be any type of structure that can contact, support, connect, or secure or anchor or anchor components of the various embodiments herein, for example. The base 110 can include, for example, a metal or non-metal tray, a metal or non-metal base plate, a metal or non-metal structure that mounts on a tray, etc. Types of metals that can be used to form the base 110 include, but are not limited to, titanium, titanium alloys, stainless steel, cobalt chromium alloys, tantalum, or niobium.

[0047] In the exemplary embodiment, the stem 130 includes a solid region 150 coated by a porous region 160 of the porous structure 120. The solid region 150 of the stem 130 is anchored to the base 110 and extends outwardly from the porous structure 120 such that the porous structure 120 surrounds the region of the stem 130 proximal to the base 110. In other embodiments, the stem 130 may be anchored to the porous structure 120. Types of metals that can be used to form the stem 130 include, but are not limited to, titanium, titanium alloys, stainless steel, cobalt chromium alloys, tantalum, or niobium.

[0048] Referring now to FIG. 4, the porous structure 120 of the implant 100 includes a plurality of connected unit cells, at least some and up to all of which have the geometric unit cell structure 200 shown in FIG. 4, illustratively. Metal types that can be used to form the illustrated unit cell structures include, but are not limited to, titanium, titanium alloys, stainless steel, cobalt chromium alloys, tantalum, or niobium. As shown in FIG. 4, each geometric unit structure includes a plurality of struts 208 including a plurality of outer struts 210. The outer struts 210 combine to define a lattice structure. The outer struts 210 cooperate to form a geometric outer structure 230. In an illustrative embodiment, the outer geometric shape is a geometric rhombic dodecahedron 215. As described below with respect to FIGS. 12A-14C, the unit cells can include an organic structure that is different from the geometric structure. In some examples, the organic structure is modified relative to the geometric structure.

[0049] As used herein, the terms "substantially," "about," "approximately," words of similar meaning, and their derivatives when used in relation to a size, shape, dimension, direction, orientation, etc., include the range associated with the stated size, shape, dimension, direction, orientation, as well as typical manufacturing tolerances, such as plus or minus 2%.

[0050] 4, the outer struts 210 further intersect with each other to define a plurality of outer vertices or outer nodes 212. Each of at least three respective groups of the outer struts 210 intersect with each other to define a respective plurality of outer nodes 212. For example, each of the outer nodes 212 is defined by three intersections of the outer struts 210 in one embodiment. Each of the outer struts 210 thus extends along a respective length from a respective first node of the outer nodes 212 to a respective second node of the outer nodes 212. Furthermore, each of the plurality of outer nodes 212 has a position in three-dimensional space (e.g., along the x-, y-, and z-directions, which are all oriented perpendicular to each other) relative to the remaining outer nodes 212 of the plurality of outer nodes 212 that define the nodes 212 of the geometric rhombic dodecahedron 215. Where the outer struts 210 define a geometric rhombic dodecahedron 215 , the struts 210 combine to define fourteen outer nodes 212 .

[0051] As shown in FIG. 3, the struts 208 include a plurality of outer struts 210 and a plurality of inner struts 220. Thus, each geometric unit cell structure 200 shown in FIG. 3 includes a plurality of outer struts 210 and a plurality of inner struts 220 that form a first geometric structure 230 and a plurality of second geometric structures 240 within the first geometric structure 230. In an exemplary embodiment, the first geometric structure 230 includes a plurality of outer struts 210. As described above with respect to FIG. 4, the plurality of outer struts 210 of FIG. 3 cooperate to form a geometric rhombic dodecahedron. Thus, the first geometric structure 230 defines a geometric rhombic dodecahedron. The inner struts 220 cross each other to define an inner node 232. In the illustrated embodiment, all of the inner struts 220 cross each other to define an inner node 232. In the illustrated embodiment, the inner struts 220 cross one another to define only a single inner node 232 and no other inner nodes. At least some, and up to all, of the connected unit cells of the porous structure 120 of the implant 100 can have the unit cell structure 200 shown in FIG. 3. Thus, the unit cell structure 200 defines only one single inner node 232 that is internal to the outer node 212.

[0052] Each of the plurality of second geometric structures 240 has an internal volume 250 substantially equal to the internal volume 250 of the other second geometric structures 240. As shown in FIG. 5, each second geometric structure 230 is formed by several inner struts 220 and several outer struts 210. Each second geometric structure 230 is illustratively a geometric trigonal trapezohedron. As shown in FIG. 3, the plurality of second geometric structures 240 in the first geometric structure 230 includes four geometric trigonal trapezohedrons such that the unit cell structure 200 is a geometric rhombic trigonal trapezohedron (GRTT). As will be understood from the following description, a rhombic trigonal trapezohedron (RTT) may be configured as a geometric RTT (GRTT) or alternatively as an organic RTT (ORTT).

[0053] It should be understood that each unit cell structure may include other types of second geometric structures. For example, as shown in FIG. 6, the unit cell structure 300 includes a plurality of outer struts 310 and a plurality of inner struts 320 that form a first geometric structure 330 and a plurality of second geometric structures 340 within the first geometric structure 330. In an exemplary embodiment, the first geometric structure 330, such as the first geometric structure 230, includes a plurality of outer struts 310 and is a geometric rhombic dodecahedron. The outer struts 310 may define a constant thickness along their entire respective lengths. Furthermore, the outer struts 310 may have equal thicknesses. The inner struts 320 may also define a constant thickness along their entire respective lengths. Furthermore, the inner struts 320 may have equal thicknesses. Furthermore, the inner struts 320 and the outer struts 310 may have equal thicknesses. Alternatively, the inner struts 320 and the outer struts 310 may have different thicknesses. In embodiments where the outer strut 310 and the inner strut 320 are cylindrical, the respective thicknesses define the diameters of the outer strut 310 and the inner strut 320, respectively.

[0054] As shown in Fig. 7, each second geometric structure 340 is formed by several inner struts 320 and several outer struts 310. Each second geometric structure 340 is illustratively a geometric octahedron (e.g., a diamond-shaped structure). As shown in Fig. 6, the plurality of second geometric structures 340 in the first geometric structure 330 includes six octahedra such that the unit cell structure 300 is a geometric rhombic octahedron (GRO).

[0055] Within the unit cell structure of the porous three-dimensional structure described above, at least one of the length and diameter of the at least one strut in each unit cell can be configured to meet predetermined or desired geometric properties of the unit cell structure. In some embodiments, at least one of the length and diameter of the at least one strut in each unit cell of the organic structure can be altered relative to the corresponding at least one strut of the geometric structure. These geometric properties can be selected from the group consisting of porosity, pore size, minimum window size, and combinations thereof. It has been advantageously discovered that certain geometric structures of the unit cell structure (described below) can optimize one or more of these geometric properties to provide a more robust and homogeneous geometry. The resulting geometry provides improved bone ingrowth while maintaining the required porous structure stability.

[0056] With reference to porosity, the porous structure 120 has a porosity of about 50% to about 75%. As discussed above, the term "about" refers to a range associated with typical manufacturing tolerances. As such, a porosity of "about 50%" may be, for example, a porosity of 50% plus or minus a typical manufacturing tolerance, such as 2% (i.e., a range of 48% to 52%). In other embodiments, the porosity of the porous three-dimensional structure is from about 20% to about 95%. In other embodiments, the porosity is in the range of about 35% to about 85%. Geometrically, the porosity of the unit cell structure depends on the ratio of strut length (a) to strut diameter (d). In FIG. 8, for example, a chart 800 of porosity (percent) versus strut length / diameter for various unit cell geometries according to various embodiments is provided. As outlined in chart 800, three particular unit cell geometries / structures were considered: a geometric rhombic dodecahedron (GRD) (see, e.g., FIG. 4), a geometric rhombic dodecahedron with four internal struts (GRD+4) (or a geometric rhombic triangular rhombohedron) (see, e.g., FIG. 3), and a geometric rhombic dodecahedron with eight internal struts (GRD+8) (or a geometric rhombic octahedron) (see, e.g., FIG. 6). For each of the structures, the porosity was taken at several a / d ratios from the design file for each unit cell structure, and the relationships for each unit cell structure were modeled by fitting the data to a fourth order polynomial of the following form:

[0057]

number

[0058] As can be seen in chart 800 of Figure 8, the RD structure generally has a greater porosity for a given a / d ratio, which is expected due to the lack of inner struts compared to the Geometry RD+4 and Geometry RD+8 structures. The porosity of the Geometry RD structure is shown by line 802. However, this reduction in porosity in the Geometry RD+4 and Geometry RD+8 structures, shown by lines 804, 806, respectively, allows designs made with Geometry RD+4 and Geometry RD+8 structures to reach a combination of lower porosity, smaller pore size, and higher window size at a constant strut diameter (fixed by the printer's build resolution) that is not possible with Geometry RD, as described in more detail below.

[0059] Referring now to Figure 9, a chart 900 of pore size and minimum window size versus porosity (percent) for various unit cell geometries / structures is provided, according to various embodiments. As seen in Figure 8, three specific unit cell structures were considered: a rhombic dodecahedron (GRD) (see, e.g., Figure 4), a geometric rhombic dodecahedron with four inner struts (GRD+4) (or a geometric rhombic triangular rhombic polyhedron) (see, e.g., Figure 3), and a geometric rhombic dodecahedron with eight inner struts (GRD+8) (or a geometric rhombic octahedron) (see, e.g., Figure 6). The pore size of the geometric rhombic dodecahedron is considered, for example, as the equivalent diameter of a sphere within the volume bounded within the unit cell of the geometric rhombic dodecahedron, and the volume was calculated by taking the volume of the geometric rhombic dodecahedron at strut length (a) and subtracting the volume of each strut within or bounded by the geometric rhombic dodecahedron. The formula provided herein for calculating pore size (PS) depends on the strut length (a), diameter (d), and porosity in decimal units (p). The formula is as follows:

[0060] For SRD structures:

[0061]

number

[0062]

number

[0063]

number

[0064] Line 902 of chart 900 shows the relationship between pore size and percent porosity for a geometric rhombic dodecahedron (SRD), line 904 shows the relationship between pore size and percent porosity for a geometric rhombic triangular hexahedron (SRD+4), and line 906 shows the relationship between pore size and percent porosity for a geometric rhombic octahedron (SRD+8).

[0065] As observed in chart 900 of FIG. 9, at lower percent porosity, the three structures generally provided similar required pore sizes. However, as a given percent porosity increases (and assuming the strut diameter remains substantially the same), the pore size required in the SRD structure to accommodate the percent porosity becomes significantly larger than the other structures, and therefore more stringent requirements are placed on the SRD structure as the required porosity increases by increasing the pore size beyond what may be effective for bone ingrowth. In other words, as the required percent porosity increases, the SRD structure becomes less effective, and this should be noted when designing porous three-dimensional structures such as those described herein.

[0066] 10, each unit cell structure 200 has a number of exterior sides 1002, with the exterior struts 210 cooperating to define a number of openings 1004 in the exterior sides 1002. The interior struts 220 of the unit cell structure 200 cooperating with the exterior struts 210 to form a number of interior openings 1006. The minimum window opening or size of each of the openings 1004, 1006 may be defined as the diameter 1008 of a circle 1010 positioned within the corresponding opening (illustratively one of the openings 1004 in FIG. 10), such that each strut 210 (or strut 220) is positioned on a tangent to the circle 1010. Thus, the length and diameter of the struts determine the size of each of the openings 1004, 1006, which in turn determines the diameter of the largest sphere that can fit therein. For example, for a given strut length, as the strut diameter increases, the minimum window opening will decrease.

[0067] These relationships are provided by the following equations, which were used to calculate the minimum window openings for all structures (e.g., SRD, SRD+4, SRD+8, etc.) to generate lines 908, 910, 912 in FIG.

[0068]

number

[0069] For purposes of chart 900, the minimum window opening is the diameter of the largest circle 1010 that can fit into each opening. In other words, it is the diameter of the inscribed circle and is therefore dependent on the strut length (a) and diameter (d). Window size vs. porosity (percent) relationship for various unit cell geometries. Line 908 of chart 900 shows the minimum window opening vs. porosity relationship for a geometric rhombic dodecahedron (GRD). Line 910 shows the minimum window opening vs. porosity relationship for a geometric rhombic triangular hexahedron (GRD+4), and line 912 shows the minimum window opening vs. porosity relationship for a geometric rhombic octahedron (GRD+8).

[0070] As can be observed in chart 900 of Figure 9, generally at all percent porosities, there is a nearly uniform gap at the minimum window opening between each unit cell structure. Thus, regardless of the percent porosity required for a given porous three-dimensional structure having a substantially constant strut diameter, for a given percent porosity, the SRD+8 structure will have a larger minimum window opening than the SRD+4 and SRD structures, and both the SRD+8 and SRD+4 structures will have a larger minimum window opening than the SRD structure.

[0071] The results in Figure 9 demonstrate that structures with inner struts, i.e. SRD+4 and to a lesser extent SRD+8, are advantageous over SRD structures. SRD+4 and SRD+8 allow smaller pore sizes for a given porosity and strut diameter. Any advantage that the SRD structures may have in porosity as a function of a / d ratio is almost completely diminished as the required a / d ratio increases. Finally, the SRD+4 and SRD+8 structures (or structures with inner struts) provide the most homogeneous structures due to the smaller difference between pore size and window size than the SRD structures.

[0072] In the porous structure 120, the ratio of the pore size of a unit cell to any of the corresponding window sizes ranges from 1.50 to 1.60. In other embodiments, the ratio may range from 1.00 to 1.10. In yet other embodiments, the ratio may range from 1.00 to 2.90. As shown in FIG. 9, in the SRTT structure of FIG. 3 and the SRO structure of FIG. 6, the difference between the pore size and the window size is substantially smaller than in the SRD structure of FIG. 4. As a result, the SRTT structure advantageously provides a more homogenous structure with a smaller difference between the pore window size and the overall pore size, and promotes bone ingrowth by providing a window size closely proportional to the pore size, especially at high levels of porosity. Although only the SRTT is referenced in FIG. 9, the conclusions would also apply to various structures including internal struts, for example structures having multiples of four internal struts.

[0073] According to various embodiments, an orthopedic implant is provided. The implant may include a porous three-dimensional structure including a lattice of connected unit cells, for example as illustrated by the unit cell structures of FIGS. 3-5. At least one unit cell may include a plurality of outer struts. The at least one unit cell may further include a first geometric structure including a plurality of outer struts and a second geometric structure sharing a subset of the plurality of outer struts of the first geometric structure and having a different geometric shape than the first geometric structure (see FIGS. 3 and 6). Additionally, at least a portion of the subset of the plurality of outer struts in the second geometric structure may intersect to form an angle substantially equal to an angle formed by an intersection of the plurality of outer struts of the first geometric structure.

[0074] As mentioned above, the first geometric structure can be, for example, a geometric rhombic dodecahedron as shown in FIG. 4. The second geometric structure can be a geometric triangular-sided irregular polyhedron (see FIG. 5). The geometric triangular-sided irregular polyhedron can be formed, for example, by inserting four struts into the first geometric structure as shown in FIG. 3. Furthermore, at least one unit cell can include four geometric triangular-sided irregular polyhedron structures within the first geometric structure as shown in FIG. 3.

[0075] Within the porous three-dimensional structure, at least one of the length and diameter of at least one strut in the lattice can be configured to meet a predetermined geometric characteristic of the lattice. In one embodiment, at least one of the length and diameter of at least one strut of the organic structure can be modified relative to at least one of the length and diameter of at least one strut of the geometric structure. As described above, these geometric characteristics can be selected from the group consisting of porosity, pore size, minimum opening size, and combinations thereof. For example, the porosity can be about 20% to about 95%. The porosity can also be about 35% to about 85%. The porosity can also be about 50% to about 75%. Furthermore, the individual strut length can be, for example, about 25% to about 175% of the average strut length of the plurality of struts. As described in more detail below, each of the above geometric structures can be modified to generate an organic structure. In one embodiment, the individual outer strut length of each of the geometric structures may also be varied to be up to about 75% to about 125% of the average strut length of the multiple outer struts of the geometric structure to generate an organic structure. In another embodiment, the individual outer strut length of each of the geometric structures may also be varied to be, for example, up to about 50% to about 150% of the average strut length of the multiple outer struts of the geometric structure.

[0076] According to various embodiments, an orthopedic implant is provided. The implant may include a porous three-dimensional structure including a plurality of repeating unit cells. Each unit cell may include a base geometric structure and a secondary geometric structure formed from a portion of the base geometric structure and having a different geometric shape than the base geometric structure. Furthermore, for a given porosity of the porous three-dimensional structure, at least one unit cell may have a pore size that is different from the pore size of the average geometric structure of the porous three-dimensional structure and a window size that is different from the window size of the average geometric structure of the porous three-dimensional structure.

[0077] 12A-13E, an organic unit cell structure 400 may be modified relative to the geometric unit cell structure 200 described above. For example, FIGS. 12A and 13A show a first or outer geometric structure 230. FIGS. 12B-12C and 13B-13E show a first or organic outer structure having node positions different from those of the corresponding first geometric structure 230. In one embodiment shown in FIG. 12A, the first geometric structure 230 is shown as a geometric rhombic dodecahedron 215 as described above. As shown in FIGS. 12B-12C, the organic structure 430 may be configured as an organic rhombic dodecahedron 415 that is modified relative to the geometric rhombic dodecahedron described above. For example, one or more of the nodes of the organic structure 430, up to all of the nodes, may be repositioned relative to the corresponding nodes of the geometric structure 230.

[0078] As shown in FIG. 12A , each of the multiple outer nodes 212 has a position in three-dimensional space (e.g., along the x-, y-, and z-directions, which are all oriented perpendicular to one another) relative to the remaining outer nodes 212 of the multiple outer nodes 212 that define the nodes 212 of the geometric rhombic dodecahedron 215.

[0079] Further, the outer nodes 212 include respective pairs of opposing nodes. As an example, the first outer node 212a and the second outer node 212b of the outer nodes 212 define a first pair of opposing outer nodes. Each node of the pair of opposing outer nodes may be spaced farther from each other than from any other node. In this regard, no outer node 212 is spaced farther from the first outer node 212a than the second outer node 212b. Further, no outer node 212 is spaced farther from the second outer node 212b than the first outer node 212a. Further, each node of the pair of opposing outer nodes may be spaced from each other by three intermediate outer nodes of the plurality of outer nodes 212 along the shortest path along the outer strut 210 between each of the opposing outer nodes of the pair. Thus, the second outer node 212b may be spaced from the first outer node 212a by three intermediate outer nodes of the plurality of outer nodes 212 along the shortest path along the outer strut 210 from the first outer node 212a to the second outer node 212b. That is, when traveling along the outer strut 210 from the first outer node 212a to the second outer node 212b along the shortest path, the path includes the three intermediate outer nodes 217a, 217b, and 217c (it being recognized that multiple such shortest paths may be defined).

[0080] The third outer node 212c and the fourth outer node 212d of the outer nodes 212 define a second pair of opposing nodes. The fifth outer node 212e and the sixth outer node 212f of the outer nodes 212 define a third pair of opposing nodes. It is noted that a first straight imaginary line 235 extends through the first outer node 212a and the second outer node 212b. A second straight imaginary line 237 extends through the third outer node 212c and the fourth outer node 212d. A third straight imaginary line 239 extends through the fifth outer node 212e and the sixth outer node 212f. The first straight imaginary line 235, the second straight imaginary line 237, and the third straight imaginary line 239 substantially intersect with each other at an intersection 241.

[0081] 1 and 12B, at least some, and up to all, of the unit cells of the porous structure 120 of the implant 100 have an organic unit cell structure 400 as shown in FIG. 12B. In some examples, the organic unit cell structure 400 is modified relative to the geometric rhombic dodecahedron 215 as shown in FIG. 4. In other examples, the organic unit cell structure 400 is designed without the aid of a previously designed geometric unit cell structure 200, such as the geometric rhombic dodecahedron described above. Thus, as shown in FIG. 12B, each organic unit structure includes a number of struts 408 including a number of outer struts 410. The outer struts 410 combine to define a lattice structure. The outer struts 410 cooperate to form an organic outer structure 430 that is modified relative to the geometric outer structure 230 of FIG. 4. In an exemplary embodiment, the organic outer structure 430 is an organic rhombic dodecahedron 415. The outer struts 410 can define a constant thickness along their entire respective lengths. Further, the outer struts 410 can have equal thicknesses. The inner struts 420 can also define a constant thickness along their entirety of their respective lengths. Further, the inner struts 420 can have equal thicknesses. Further, the inner struts 420 and the outer struts 410 can have equal thicknesses. Alternatively, the inner struts 420 and the outer struts 410 can have different thicknesses. In embodiments where the outer struts 410 and the inner struts 420 are cylindrical, the respective thicknesses define the diameters of the outer struts 410 and the inner struts 420, respectively.

[0082] The outer struts 410 therefore intersect with one another to define a number of outer vertices or outer nodes 412. Each of the outer nodes 412 is defined by three intersections of the outer struts 410. Each of the outer struts 410 therefore extends along its respective length from a first node of each of the outer nodes 412 to a second node of each of the outer nodes 412. When the outer struts 410 form an organic rhombic dodecahedron 415, the struts 410 combine to define fourteen outer nodes 412. Furthermore, each of the plurality of outer nodes 412 has a position in three-dimensional space (e.g., along the x-, y-, and z-directions, which are all oriented perpendicular to one another) relative to the remaining outer nodes 412 of the plurality of outer nodes 412 that define the nodes 412 of the organic rhombic dodecahedron 415.

[0083] As described above, the position of at least one exterior node 412 of the organic rhombic dodecahedron 415, including the plurality of exterior nodes 412 up to all of the exterior nodes, is different from the corresponding at least one exterior node 212 of the geometric rhombic dodecahedron. With reference to FIG. 12B, the exterior struts 410 and the exterior nodes 412 combine to substantially define a geometric structure 430 within 25% of the geometric rhombic dodecahedron 215. For example, the position of the at least one exterior node 412 of the organic rhombic dodecahedron 415 is altered by up to 25% relative to the position of the corresponding at least one exterior node 212 of the geometric rhombic dodecahedron 215 shown in FIG. 12A. For example, the position of the plurality of exterior nodes 412 of the organic rhombic dodecahedron 415 is altered by up to 25% relative to the position of the corresponding at least one exterior node 212 of the geometric rhombic dodecahedron 215. Thus, the exterior struts 410 and exterior nodes 412 combine to substantially define a geometric structure within 25% of the geometric rhombic dodecahedron 215. Additionally, the location of at least one, and up to a plurality of, the exterior nodes 412 of the organic rhombic dodecahedron 415 shown in Figure 12B may be the same as the location of a corresponding at least one, and up to a plurality of, the exterior nodes 212 of the geometric rhombic dodecahedron 215 shown in Figure 12A. As used herein with reference to percentages, the term "within" includes the recited percentages.

[0084] The location of the exterior node 412 of the organic rhombic dodecahedron 415 can be represented by the following equation:

[0085]

number

[0086] In another embodiment, referring to FIG. 12C , the outer struts 410 and the outer nodes 412 combine to define a geometric structure 430 that is substantially within 50% of the geometric rhombic dodecahedron 215. For example, the position of at least one outer node 412 of the organic rhombic dodecahedron 415 is altered by up to 50% relative to the position of the corresponding at least one outer node 212 of the geometric rhombic dodecahedron 215 shown in FIG. 12A. For example, the positions of the plurality of outer nodes 412 of the organic rhombic dodecahedron 415 are altered by up to 50% relative to the positions of the corresponding plurality of outer nodes 212 of the geometric rhombic dodecahedron 215. Thus, the outer struts 410 and the outer nodes 412 combine to define a geometric structure that is substantially within 50% of the geometric rhombic dodecahedron 215. Furthermore, the position of at least one, and up to a number of, the outer nodes 412 of the organic rhombic dodecahedron 415 shown in FIG. 12C may be the same as the position of at least one, and up to a number of, the corresponding outer nodes 212 of the geometric rhombic dodecahedron 215 shown in FIG. 12A.

[0087] In this manner, as shown in Figures 12A-12C, at least some of the outer nodes 412 of the organic rhombic dodecahedron are repositioned relative to the outer nodes 212 of the geometric rhombic dodecahedron 215. Thus, when a first porous three-dimensional structure including the organic outer structure 430 is superimposed on a second porous three-dimensional structure including the geometric structure 230 in the same position and orientation, at least some of the outer nodes 412 of the first porous three-dimensional structure are offset relative to corresponding some of the nodes 212 of the second porous three-dimensional structure. In some embodiments, other outer nodes 412 of the plurality of outer nodes 412 of the first porous three-dimensional structure coincide with corresponding other outer nodes 212 of the plurality of nodes 212 of the second porous three-dimensional structure. The organic outer structure 430 is otherwise substantially identical to the geometric outer structure 230, apart from the repositioned outer nodes 412 and the resulting changes to the corresponding struts 410, which will now be described. For example, the organic outer geometric shape 430 and the resulting porous three-dimensional structure have the same number of struts and nodes, respectively, as the outer geometric structure 230 and the resulting porous three-dimensional structure.

[0088] It has been found that the porous three-dimensional structure with the organic structure 430 has a ductility that is greater than the ductility of the porous three-dimensional structure including the geometric outer structure 230. Furthermore, the porous three-dimensional structure including the organic outer structure 430 has suitable structural integrity when implanted in the human anatomy.

[0089] Specifically, as a result of the rearranged outer nodes 412, at least one or more, and up to all, of the struts 410 of the organic outer structure 430 have at least one geometric characteristic that differs from the corresponding struts 210 of the geometric outer structure 230. As discussed above, the geometric characteristic may include at least one of the length, orientation, and path type (e.g., straight or curved) of the struts 210. For example, at least one or more of the outer struts 410 that partially define the rearranged outer nodes 412 may be longer or shorter than the corresponding outer struts 210 of the corresponding geometric rhombic dodecahedron. In this regard, the outer struts 410 extend along their respective lengths from and to each pair of outer nodes 412, and at least some of the lengths of the outer struts 410 differ from one another. For example, the individual lengths of the outer struts 410 may be altered to be, for example, about 75% to about 125% of the average strut length of the plurality of outer struts 410.

[0090] Additionally, the outer struts 410 may extend between each adjacent node 412 defined by the outer struts 410 along any suitable path along their length. For example, one or more of the struts 410 partially defining the repositioned outer nodes 412 may extend along straight and linear paths along their entire length and may have a different orientation than the outer struts 210 of the corresponding geometric structure 230. Alternatively, at least a portion of at least one or more of the outer struts 410 partially defining the repositioned outer nodes 412 may be curved along their length between a first outer node 412 of each of the plurality of nodes and a second outer node 412 of each of the plurality of nodes. Thus, at least one curved strut 410 intersects with two different other pairs of struts 410 to define the respective first and second outer nodes 412. In one embodiment, at least a portion of the outer struts 410 extend along a curved path. Alternatively or additionally, at least a portion of at least one or more of the outer struts 410 may be angled and therefore curved. It will be appreciated that all of the outer struts 410 shown in Figures 12B-12C may be straight (see Figures 13C and 13E). Alternatively, all of the outer struts 410 may be curved.

[0091] 12B, the outer struts 410 include a longest outer strut and a shortest outer strut. No outer struts 410 extend between adjacent outer nodes 412 along a path longer than the path of the longest outer strut. Conversely, no outer struts 410 extend between adjacent outer nodes 412 along a path shorter than the path of the longest outer strut. If the position of the outer nodes 412 of the organic structure 430 is altered by 25% relative to the position of the corresponding geometric outer structure 230, the length of the shortest outer strut 410 is about 60% or more of the length of the longest outer strut 410.

[0092] 12C, the outer struts 410 include a longest outer strut and a shortest outer strut. No outer strut 410 extends between each adjacent outer node 412 along a path longer than the path of the longest outer strut. Conversely, no outer strut 410 extends between each adjacent outer node 412 along a path shorter than the path of the longest outer strut. If the position of the outer node 412 is changed by 50% relative to the position of the outer node 212 of the corresponding geometric outer structure 230, the length of the shortest outer strut 410 is about ⅓ or more of the length of the longest outer strut 410.

[0093] 12B-12C, outer nodes 412 include a first outer node 412a and a second outer node 412b opposite the first outer node 412a to define a first pair of opposing nodes. Outer nodes 412 further include a third outer node 412c and a fourth outer node 412d opposite the third outer node 412c to define a second pair of opposing nodes. Outer nodes 412 further include a fifth outer node 412e and a sixth outer node 412f opposite the fifth outer node 412e to define a third pair of opposing nodes.

[0094] As discussed above with respect to FIG. 12A, each node of a pair of opposing outer nodes 412 may be spaced farther from each other than from any other node. In this regard, no outer node 412 is spaced farther from the first outer node 412a than the second outer node 412b. Moreover, no outer node 412 is spaced farther from the second outer node 412b than the first outer node 412a. Moreover, each node of a pair of opposing outer nodes may be spaced from each other by three intermediate outer nodes of the plurality of outer nodes 412 along the shortest path along the outer strut 410 between each node of the pair of opposing outer nodes. Thus, the second outer node 412b is spaced from the first outer node 412 by three intermediate outer nodes of the plurality of outer nodes 412 along the shortest path along the outer strut 410 from the first outer node 412a to the second outer node 412b. That is, when traveling along the outer pillar 410 from the first outer node 412a to the second outer node 412b along the shortest path, the path includes the three intermediate outer nodes 417a, 417b, and 417c (it will be appreciated that multiple such shortest paths may be defined).

[0095] A first straight imaginary line 419 extends geometrically through the first outer node 412a and the second outer node 412b. A second straight imaginary line 421 extends through the third outer node 412c and the fourth outer node 412d. A third straight imaginary line 423 extends through the fifth outer node 412e and the sixth outer node 412f. The first imaginary line 419 and the second straight imaginary line 421 intersect with each other at a first intersection point 424a with respect to a select view of the porous three-dimensional structure. The third straight line 423 intersects with the first straight imaginary line 419 at a second intersection point that is offset from the first intersection point with respect to the select view of the porous three-dimensional structure. The third straight imaginary line 423 may also intersect with the second straight imaginary line 421 at a third intersection point that is offset from either or both of the first intersection point and the second intersection point with respect to the select view of the porous three-dimensional structure.

[0096] The organic unit cell structure 400 of FIGS. 12B-12C may be modified relative to the geometric unit cell structure 200 such that the outer nodes 412 of the organic unit cell structure 400 may be repositioned in any suitable direction relative to the corresponding outer nodes 212 of the geometric unit cell structure 200. Thus, the outer nodes 412 of a first half of the organic unit cell structure 400 may be repositioned in a first direction relative to the corresponding outer nodes 212 of the geometric unit cell structure 200. The outer nodes 412 of a second half of the organic unit cell structure 400 may be repositioned in a second direction, different from the first direction, relative to the corresponding outer nodes 212 of the geometric unit cell structure 200. The first and second directions may be opposite to each other, perpendicular to each other, or oblique to each other. The first and second halves of the organic unit cell structure 400 are separated from each other by a plane that bisects the organic unit cell structure 400. Thus, in some embodiments, regardless of planar orientation (i.e., for all orientations of the planar surface), at least some, and up to all, of the outer nodes 412 of the first half of the organic unit cell structure 400 are reoriented in a different direction relative to the corresponding outer nodes 212 of the geometric unit cell structure 200, and at least some, and up to all, of the outer nodes 412 of the second half of the organic unit cell structure 400 are reoriented in a different direction relative to the corresponding outer nodes 212 of the geometric unit cell structure 200.

[0097] 13A, as described above with respect to FIG. 3, the struts 208 include a plurality of outer struts 210 that define a first geometric structure 230. The struts 208 further include a plurality of inner struts 220 that combine with the outer struts 210 to form a plurality of second geometric structures 240 within the first geometric structure 230. In an exemplary embodiment, the first geometric structure 230 includes a plurality of outer struts 210. As described above, the plurality of outer struts 210 of FIG. 3 cooperate to form a geometric rhombic dodecahedron. Thus, the first geometric structure 230 defines a geometric rhombic dodecahedron. The inner struts 220 intersect with each other to define an inner node 232. Specifically, all of the inner struts 220 intersect with each other to define the inner node 232. Furthermore, each of the inner struts 220 extends from a respective outer node 212 to the inner node 232. In the illustrated embodiment, the interior struts 220 cross each other to define only a single interior node 232 and no other interior nodes. Thus, the geometric unit cell 200 defines only one single interior node 232 that is interior to the exterior node 212.

[0098] The outer struts 210 can define a constant thickness along their entire respective lengths. Moreover, the outer struts 210 can have an equal thickness. The inner struts 220 can also define a constant thickness along their entire respective lengths. Moreover, the inner struts 220 can have an equal thickness. Moreover, the inner struts 220 and the outer struts 210 can have an equal thickness. Alternatively, the inner struts 220 and the outer struts 210 can have different thicknesses. In embodiments where the outer struts 210 and the inner struts 220 are cylindrical, the respective thicknesses define the diameters of the outer struts 210 and the inner struts 220, respectively.

[0099] As shown in FIG. 13A, each of the plurality of second geometric structures 240 has an internal volume substantially equal to the internal volume of the other second geometric structures 240. Each second geometric structure 230 is formed by several inner struts 220 and several outer struts 210. Each second geometric structure 230 is illustratively a geometric triangular-faced irregular polyhedron. As shown in FIG. 3, the plurality of second geometric structures 240 in the first geometric structure 230 includes four geometric triangular-faced irregular polyhedrons, such that the unit cell structure 200 is a geometric rhombic triangular-faced irregular polyhedron (GRTT).

[0100] The first geometric structure 230 includes a first, second, and third pair of outer nodes 212, as described above with respect to FIG. 12A. Thus, a first straight imaginary line 235 extends through the first outer node 212a and the second outer node 212b. A second straight imaginary line 237 extends through the third outer node 212c and the fourth outer node 212d. A third straight imaginary line 239 extends through the fifth outer node 212e and the sixth outer node 212f. The first straight imaginary line 235, the second straight imaginary line 237, and the third straight imaginary line 239 substantially intersect each other at the inner node 232.

[0101] 13B-13C, the position of a given outer node 412 of an organic rhombic dodecahedron 415 is altered by up to 25% relative to the position of the corresponding outer node 212 of the geometric rhombic dodecahedron 215 described above. In another embodiment shown in FIG. 13D-13E, the position of a given outer node 412 of an organic rhombic dodecahedron 415 is altered by up to 50% relative to the position of the corresponding outer node 212 of the geometric rhombic dodecahedron 215 described above. Furthermore, in both FIG. 13B and FIG. 13C, the struts 408 of the first organic structure 430 can include a plurality of inner struts 420 that combine with the outer struts 410 to form a plurality of second organic structures 440 within the first organic structure 430. The inner struts 420 cross each other to define inner nodes 432 at the intersections of the inner struts. Specifically, in the exemplary embodiment, all of the inner struts 420 cross one another to define the inner node 432. Further, each of the inner struts 420 extends from a different one of the plurality of outer nodes 412 to the inner node 432. In the illustrated embodiment, the inner struts 420 cross one another to define only a single inner node 432 and no other inner nodes. Thus, the unit cell structure 400 defines only one single inner node 432 that is interior to the outer nodes 412.

[0102] In an exemplary embodiment, the first organic structure 430 includes a plurality of outer struts 410. As described above, the plurality of outer struts 410 cooperate to form an organic rhombic dodecahedron. Each second organic structure 440 is illustratively an organic triangular tetrahedron. The plurality of organic second structures 440 in the organic first structure 430 include four organic triangular tetrahedrons such that the unit cell structure 400 is an organic rhombic dodecahedron (ORTT). The organic triangular tetrahedron is modified with respect to the above-mentioned geometric triangular tetrahedron. For example, at least one of the inner nodes 432 and at least one of the outer nodes 412 (including a plurality of up to all of the outer nodes 412) are repositioned with respect to the corresponding at least one of the inner nodes and at least one of the outer nodes (including a plurality of up to all of the outer nodes) of the above-mentioned geometric triangular tetrahedron. It will thus be understood that the resulting organic rhombic triangular irregular polyhedron is modified relative to the geometric rhombic triangular irregular polyhedron described above, for example, at least one of the interior nodes 432 and at least one of the exterior nodes 412 (including a plurality up to all of the exterior nodes 412) are repositioned relative to the corresponding at least one of the interior nodes and at least one of the exterior nodes (including a plurality up to all of the exterior nodes) of the geometric rhombic triangular irregular polyhedron described above, respectively.

[0103] Each second organic structure 440 is formed by several inner struts 420 and several outer struts 410. Each second organic structure 440 is illustratively an organic triangular squarish polyhedron. As described above, the positions of at least one or more, and up to all, of the outer nodes 412 of the organic structure 430 are changed relative to the outer nodes 212 of the second geometric structure 240. Furthermore, the positions of the internal nodes 432 of the second organic structure 440 are changed relative to the positions of the internal nodes 232 of the second geometric structure 240. In one exemplary embodiment shown in Figures 13B-13C, the positions of at least one of the inner nodes 432 and at least one of the outer nodes 412 are changed by up to 25% relative to the positions of the internal nodes 232, as shown in Figures 3B-3C. In another exemplary embodiment shown in Figures 13D-13E, the position of at least one of the inner nodes 432 and at least one of the outer nodes 412 is changed by up to 50% relative to the position of the inner node 232 as shown in Figures 3B-3C. As described above with respect to Figures 13B-13C, the inner struts 420 of the first organic structure 430, the second organic structure 440 of Figures 13D-13E cross each other to define only a single inner node 432 and no other inner nodes. Thus, the unit cell structure 400 defines only one single inner node 432 that is internal to the outer node 412.

[0104] 13B-13E, the first organic structure 430 includes a first, second, and third pair of outer nodes 412, as described above with respect to FIGS. 12B-12C. Thus, a first straight imaginary line 419 extends through the first outer node 412a and the second outer node 412b. A second straight imaginary line 421 extends through the third outer node 412c and the fourth outer node 412d. A third straight imaginary line 423 extends through the fifth outer node 412e and the sixth outer node 412f. At least one or more, and up to all, of the first straight imaginary line 419, the second straight imaginary line 421, and the third straight imaginary line 423 are offset from the inner node 232.

[0105] 13B-13E may be modified relative to the geometric unit cell structure 200 such that the outer nodes 412 of the organic unit cell structure 400 may be repositioned in any suitable orientation relative to the corresponding outer nodes 212 of the geometric unit cell structure 200. Thus, the outer nodes 412 of a first half of the organic unit cell structure 400 may be repositioned in a different orientation relative to the corresponding outer nodes 212 of the geometric unit cell structure 200. Similarly, the outer nodes 412 of a second half of the organic unit cell structure 400 may be repositioned in a different orientation relative to the corresponding outer nodes 212 of the geometric unit cell structure 200. The first and second halves of the organic unit cell structure 400 are separated from one another by a plane that bisects the organic unit cell structure 400, with the inner nodes 432 lying on the plane. Thus, in some embodiments, regardless of planar orientation (i.e., for all orientations of the planar surface), at least some, and up to all, of the outer nodes 412 of the first half of the organic unit cell structure 400 are reoriented in a different direction relative to the corresponding outer nodes 212 of the geometric unit cell structure 200, and at least some, and up to all, of the outer nodes 412 of the second half of the organic unit cell structure 400 are reoriented in a different direction relative to the corresponding outer nodes 212 of the geometric unit cell structure 200.

[0106] As a result of the repositioned at least one node of the organic structure 430, at least one or more, and up to all, of the inner struts 420 of the organic structure 430 have at least one characteristic that differs from the corresponding inner struts 220 of the geometric structure 230. The characteristic may include at least one of the length, orientation, and path type (e.g., straight or curved) of the inner struts 420. For example, at least one or more of the inner struts 420 that partially define the repositioned inner node 432 may be longer or shorter than the corresponding inner struts 220 of the corresponding geometric structure 230. In this regard, the inner struts 420 extend from their respective outer nodes 412 to the inner node 432 along their respective lengths, and the lengths of at least some of the inner struts 420 differ from one another. At least one or more, and up to all, of the outer pillars 410 of the organic outer structure 430 also have at least one geometric characteristic that is different from the corresponding pillars 210 of the geometric outer structure 230, as described above with respect to Figures 12B-12C.

[0107] Further, the inner struts 420 shown in Figures 13B-13E can extend from their respective outer nodes 412 to the inner nodes 432 along any suitable path along their length. For example, one or more of the inner struts 420 of the second organic structure 440 can extend along a straight line and linear path along their entire length and can have a different orientation than the corresponding inner struts 220 of the second geometric structure 240. It is understood that all of the inner struts 420 shown in Figures 13B-13E can extend along their respective straight line paths from their respective outer nodes 412 to the inner nodes 432. Alternatively, at least a portion of at least one or more, and up to all, of the inner struts 420 may be inner struts that are curved along their length from their respective outer nodes 412 to the inner nodes 432. In one embodiment, at least a portion of the inner struts 420 may extend along a curved path. Alternatively or additionally, at least a portion of at least one or more of the inner struts 420 may be angled and therefore curved. Alternatively, all of the inner struts 420 can be curved.

[0108] It has been found that the porous three-dimensional structure comprising the first organic structure 430 and the second organic structure 440 has a ductility greater than that of the porous three-dimensional structure comprising the first geometric structure 230 and the second geometric structure 240. Furthermore, the porous three-dimensional structure comprising the first organic structure 430 and the second organic structure 440 has suitable structural integrity when implanted in the human anatomy.

[0109] It should be understood that each unit cell structure may include other types of second organic structures. For example, the organic unit cell structure may include a plurality of outer struts 410 that define a first organic structure 430 as described above. The modified unit cell structure may further include a plurality of inner struts 420 that, in combination with the outer struts 410, define a plurality of organic second or inner structures. Each of the organic inner structures may be configured as a modified octahedron. Thus, in one embodiment, the organic unit cell structure may include eight inner struts 420 as described above with respect to FIG. 6. Thus, the plurality of second organic structures within the first organic structure may include six geometric octahedra such that the organic unit cell structure is a modified or organic rhombohedron, whereby the positions of at least some of the nodes of the first organic structure and at least some of the nodes of the second organic structure are relocated relative to the nodes of the first geometric structure and the nodes of the second geometric structure.

[0110] In one embodiment, the porous three-dimensional structure having the organic outer structure 430 and the organic inner structure 440 has a porosity of about 50% to about 75%. For example, the porous three-dimensional structure having the organic outer structure 430 and the organic inner structure 440 can have a porosity of about 55% to about 65%. Furthermore, as described above with respect to the geometric outer structure 230 and the geometric inner structure 240, the outer struts 410 and the inner struts 420 define a plurality of openings in the organic porous three-dimensional structure, each opening of the plurality of openings having a window size, and the interior volume of each organic structure 430 and 440 has a pore size. As described above, the pore size can be considered as the equivalent diameter of a sphere in the volume bounded within the unit cell having the organic structure 430.

[0111] Referring to FIG. 14, the percentage of pores of a porous three-dimensional structure including the unit cell of FIG. 13C (e.g., ORTT where all struts 410 and 420 are straight and linear) where the porous three-dimensional structure has a porosity of about 55% and the node position is changed by 25% relative to the GRTT. As shown, the percentage of pores of the three-dimensional structure having a pore size of less than 0.1 mm is less than about 14.3 percent. For example, less than about 2 percent of the pores have a pore size of less than 0.1 mm. Furthermore, FIG. 14 shows that about 50 percent of the pores of the three-dimensional structure have a pore size of more than 0.2 mm. For example, about 50 percent of the pores of the three-dimensional structure have a pore size of about 0.2 mm to about 0.36 mm.

[0112] Referring to FIG. 15, the percentage of pores of a porous three-dimensional structure including the unit cell of FIG. 13C (e.g., ORTT where all struts 410 and 420 are straight and linear) where the porous three-dimensional structure has a porosity of about 65% and the position of at least one of the nodes is changed by 25% relative to the GRTT. As described above with respect to FIG. 14, the percentage of pores of the three-dimensional structure having a pore size of less than 0.1 mm is less than about 14.3 percent. For example, less than about 1.5 percent of the pores have a pore size of less than 0.1 mm as shown in FIG. 15. Furthermore, FIG. 15 shows that about 50 percent of the pores of the three-dimensional structure have a pore size of more than 0.3 mm. For example, about 50 percent of the pores of the three-dimensional structure have a pore size of about 0.3 mm to about 0.7 mm. In particular, about 50 percent of the pores of the three-dimensional structure have a pore size of about 0.3 mm to about 0.5 mm. 14-15 further confirm that about 50 percent of the pores in the three-dimensional structure having ORTT unit cells may have a pore diameter in the range of about 0.2 mm to about 0.7 mm. For example, about 50 percent of the pores in the three-dimensional structure having ORTT unit cells may have a pore diameter in the range of about 0.2 mm to about 0.5 mm.

[0113] Further, as described above with respect to the geometric structures, the ratio of the pore size of the organic structure of the porous three-dimensional structure to the window size of each opening of the organic structure can be in the range of 1.00 to 2.90. In some examples, it is recognized that at least 90 percent of the organic structures have a ratio of the pore size to the window size of each opening in the organic structure in the range of 1.00 to 2.90. For example, as described above with respect to the geometric structures, in one embodiment, the ratio of the pore size of each organic structure to the window size of each opening of the organic structure is in the range of 1.00 to 1.10. In some examples, it is recognized that at least 90 percent of the organic structures have a ratio of the pore size to the window size of each opening in the organic structure in the range of 1.00 to 2.90. In another example, as described above with respect to the porous three-dimensional structures having geometric unit cells, the ratio of the pore size of the organic unit cell to any of its corresponding window sizes is in the range of 1.50 to 1.60. It is recognized that in some embodiments, at least 90 percent of the organic unit cells have a ratio of pore size to any of their corresponding window sizes within the range of 1.50 to 2.60.

[0114] 12A-13E, a method is provided for designing a unit cell as described herein having one or both of a first and a second porous organic three-dimensional structure configured to promote bone ingrowth when implanted in a human body. The method can include applying a modification factor to a first geometric unit cell design. The first geometric unit cell design includes a number of first or outer struts 210, such as three outer struts 210, that intersect with each other to define a number of first or outer nodes 212, each of the first struts 210 having a respective first length, and the first nodes 212 defining a first relative position with respect to each other. In one embodiment, the respective first lengths of the first struts 210 are all substantially equal to each other. In another embodiment, the respective first lengths of some of the first struts are different from the respective first lengths of at least some other of the first struts 210. The first unit cell design can be provided by the method described above. The modification factor can be up to 50%, such as up to 25% in the manner described above. In one embodiment, the applying step can be performed using the 3-matic software package available from Materialise, having a place of business in Leuven, Belgium.

[0115] The applying step produces a second unit cell design having a number of second or outer struts 410 that cross each other to define a number of second or outer nodes 412. The number of outer nodes 412 is equal to the number of outer nodes 212, and the number of outer struts 410 is equal to the number of outer struts 210. Each of the outer struts 410 has a respective first length, and the outer nodes 412 define a second relative position with respect to each other that is different from the first relative position. The respective first lengths of at least some of the outer struts 410 are different from the respective first lengths of at least some others of the outer struts 410. Furthermore, the respective first lengths of at least some of the outer struts 410 are different from the respective first lengths of at least some of the corresponding outer struts 210. Alternatively, the organic three-dimensional structures 430 and 440 can be designed without the aid of previously designed geometric structures 230 and 240, respectively. It is recognized that manufacturing tolerances may result in different strut lengths. However, the different strut lengths described herein refer to different lengths excluding manufacturing tolerances.

[0116] Once the second unit cell design is generated, manufacturing instructions are created for manufacturing a porous three-dimensional structure including a plurality of interconnected unit cells, each having the second unit cell design. The porous three-dimensional structure can be manufactured on-site. Alternatively, the manufacturing instructions may be transmitted to a third party manufacturer for manufacturing the porous three-dimensional structure.

[0117] According to various embodiments, an orthopedic implant is provided. The implant may include a porous three-dimensional structure including a plurality of unit cells. Each unit cell may include an outer geometric structure having a first geometric shape and including a plurality of first struts. Each unit cell may further include an inner geometric structure having a second geometric shape and may further include a plurality of second struts connected with a portion of the plurality of first struts to form the inner geometric structure within the outer geometric structure.

[0118] According to various embodiments, the outer geometric structure can be a rhombic dodecahedron. The inner geometric structure can be a triangular-sided squarish polyhedron. The triangular-sided squarish polyhedron can be formed by inserting four struts into the outer geometric structure. Furthermore, at least one unit cell can include a geometric structure of four triangular-sided squarish polyhedrons within the outer geometric structure.

[0119] As mentioned above, the orthopedic implant may include a porous three-dimensional structure including a plurality of repeating unit cells having a unit cell structure. The unit cell structure may define a geometric or organic geometric structure. It is therefore recognized that the porous three-dimensional structure may include a plurality of groups of outer struts that define a respective first geometric or organic structure. Furthermore, some of the unit cell structures may be surrounded by or otherwise disposed inwardly relative to other unit cell structures of the porous three-dimensional structure of the orthopedic implant. As a result, when the unit cell structures are combined to define the porous three-dimensional structure, the outer struts of a particular unit cell structure may define the outer struts of an adjacent unit cell structure. Furthermore, it is recognized that the inner struts of a particular unit cell structure may define the outer struts of an adjacent unit cell structure when the unit cell structures include inner struts that define a second geometric or organic structure. Conversely, the outer struts of a particular unit cell structure may define the interior structure of the adjacent unit cell structure. Thus, any suitable combination of struts in the porous three-dimensional structure of an orthopedic implant can define outer struts of the type described herein, regardless of whether there are other struts positioned outwardly from or extending from the outer struts. Similarly, any suitable combination of struts in the porous three-dimensional structure of an orthopedic implant can define inner struts of the type described herein extending from each outer strut to an inner node. In some examples, the unit cell structure can consist of, or consist essentially of, the outer struts that define the outer nodes. In other examples, the unit cell structure can consist of, or consist essentially of, the outer struts that define the outer nodes and the inner struts that define the inner nodes.

[0120] Manufacturing Process The porous three-dimensional metal structures described above can be fabricated using a variety of different additive manufacturing techniques. For example, according to various embodiments, a method for manufacturing a porous three-dimensional structure 120 includes depositing and scanning successive layers of metal powder with a beam. The beam (or scanning beam) can be an electron beam. The beam (or scanning beam) can be a laser beam.

[0121] For the various methods described herein, the metal powder can be sintered to form a porous three-dimensional structure. Alternatively, the metal powder can be melted to form a porous three-dimensional structure. A successive layer of metal powder can be deposited on a solid base (see above for explanation of base). In various embodiments, the types of metal powder that can be used include, but are not limited to, titanium, titanium alloy, stainless steel, cobalt chromium alloy, tantalum, or niobium powder.

[0122] For various methods described herein, the geometric characteristic can be selected from the group consisting of porosity, pore size, minimum opening size, and combinations thereof. The porosity can be about 20% to about 95%. The porosity can also be about 40% to about 80%. The porosity can also be about 50% to about 75%. Additionally, the strut length can be varied to be about 25% to about 175% of the average strut length of the plurality of struts. The individual lattice strut length can also be varied, for example, to be about 50% to about 150% of the average strut length of the plurality of outer struts. The individual outer strut length can also be varied, for example, to be about 75% to about 125% of the average strut length of the plurality of outer struts. Additionally, the unit cell can have a pore size smaller than the pore size of the first geometric structure. Additionally, the unit cell can have a window size larger than the window size of each of the plurality of second geometric structures.

[0123] For the various methods described, the first geometric structure may be a rhombic dodecahedron. Each of the second geometric structures may be a triangular-sided squaric polyhedron. The triangular-sided squaric polyhedron may be formed by inserting four struts into the first geometric structure. Additionally, at least one unit cell may include a geometric structure of four triangular-sided squaric polyhedrons within the first geometric structure.

[0124] In various embodiments, a method for fabricating a porous three-dimensional structure is provided, the method including applying a flow of metal particles to a base at a predetermined rate to form a porous three-dimensional structure including a plurality of unit cells and having predetermined geometric properties, each unit cell including a plurality of outer struts and a plurality of inner struts. Each unit cell can include a first geometric structure including a plurality of outer struts and a plurality of second geometric structures formed from a plurality of inner struts within the first geometric structure. In various embodiments, types of metal particles that can be used include, but are not limited to, titanium, titanium alloy, stainless steel, cobalt chromium alloy, tantalum, or niobium particles.

[0125] The predetermined velocity may be a critical velocity required for the metal particles to bond upon impact with the base, the critical velocity being greater than 340 m / s.

[0126] The method may further include applying a laser at a predetermined power setting onto an area of ​​the base where the stream of metal particles impinges.

[0127] The first geometric structure may be a rhombic dodecahedron. In some embodiments, each of the second geometric structures may be a triangular-sided irregular polyhedron. That is, four triangular-sided irregular polyhedrons may be formed by inserting four struts into the first geometric structure. In some embodiments, an octahedron may be formed, for example, by inserting eight inner struts into the first geometric structure. In this case, six octahedral geometric structures may be provided in the first geometric structure.

[0128] According to various embodiments, a method for manufacturing a porous three-dimensional structure is provided, the method including introducing a continuous feed of a metal wire onto a base surface and applying a beam at a predetermined power setting to the area where the metal wire contacts the base surface to form a porous three-dimensional structure including a plurality of unit cells and having predetermined geometric characteristics. Each unit cell can include a plurality of outer struts and a plurality of inner struts, and each unit cell can include a first geometric structure including a plurality of outer struts and a plurality of second geometric structures formed from a plurality of inner struts within the first geometric structure. The beam (or scanning beam) can be an electron beam. The beam (or scanning beam) can be a laser beam. In various embodiments, the types of metal wire that can be used include, but are not limited to, titanium, titanium alloy, stainless steel, cobalt chromium alloy, tantalum, or niobium wire.

[0129] The first geometric structure may be a rhombic dodecahedron. In some embodiments, each of the second geometric structures may be a triangular-sided irregular polyhedron. That is, four triangular-sided irregular polyhedrons may be formed by inserting four struts into the first geometric structure. In some embodiments, an octahedron may be formed, for example, by inserting eight inner struts into the first geometric structure. That is, six octahedral geometric structures may be provided in the first geometric structure.

[0130] According to various embodiments, a method for manufacturing a porous three-dimensional structure is provided, the method comprising introducing a continuous feed of polymeric material embedded in a metal element onto a base surface. The method may further comprise applying heat to the area where the polymeric material contacts the base surface to form a porous three-dimensional structure comprising a plurality of unit cells and having a predetermined geometric characteristic. Each unit cell may comprise a plurality of outer struts and a plurality of inner struts. Each unit cell comprises a first geometric structure comprising a plurality of outer struts and a plurality of second geometric structures formed from some of the inner struts and some of the outer struts within the first geometric structure. The metal element may be a metal powder. In various embodiments, the continuous feed of polymeric material may be delivered through a heated nozzle, thus eliminating the need to apply heat to the area where the polymeric material contacts the base surface to form the porous three-dimensional structure. In various embodiments, the type of metal element that may be used to embed the polymeric material may include, but is not limited to, titanium, titanium alloy, stainless steel, cobalt chromium alloy, tantalum, or niobium.

[0131] The method may further include scanning the porous three-dimensional structure with a beam to burn off the polymeric material. The beam (or the scanning beam) may be an electron beam. The beam (or the scanning beam) may be a laser beam.

[0132] The first geometric structure may be a rhombic dodecahedron. In various embodiments, each of the second geometric structures may be a triangular-sided irregular polyhedron. That is, four triangular-sided irregular polyhedrons may be formed by inserting four struts into the first geometric structure. In various embodiments, an octahedron may be formed, for example, by inserting eight inner struts into the first geometric structure. That is, six octahedral geometric structures may be provided in the first geometric structure.

[0133] According to various embodiments, a method for manufacturing a porous three-dimensional structure is provided, the method comprising introducing a metal slurry through a nozzle to a base surface to form a porous three-dimensional structure including a plurality of unit cells and having predetermined geometric characteristics. Each unit cell may include a plurality of outer struts and a plurality of inner struts. Each unit cell may include a first geometric structure including a plurality of outer struts and a plurality of second geometric structures formed from some of the inner struts and some of the outer struts in the first geometric structure. In various embodiments, the nozzle is heated to a temperature required to bond the metal elements of the metal slurry to the base surface. In various embodiments, the metal slurry is an aqueous suspension containing metal particles along with one or more additives (liquid or solid) to improve the manufacturing process or the performance of the porous three-dimensional structure. In various embodiments, the metal slurry is an organic solvent suspension containing metal particles along with one or more additives (liquid or solid) to improve the manufacturing process or the performance of the porous three-dimensional structure. In various embodiments, types of metal particles that may be utilized in the metal slurry include, but are not limited to, titanium, titanium alloys, stainless steel, cobalt chromium alloys, tantalum, or niobium particles.

[0134] The first geometric structure may be a rhombic dodecahedron. In some embodiments, each of the second geometric structures may be a triangular-sided squarish polyhedron. That is, four triangular-sided squarish polyhedrons may be formed by inserting four struts into the first geometric structure. In various embodiments, an octahedron may be formed, for example, by inserting eight inner struts into the first geometric structure. That is, six octahedral geometric structures may be provided in the first geometric structure.

[0135] According to various embodiments, a method for manufacturing a porous three-dimensional structure is provided, the method including introducing a successive layer of molten metal onto a base surface to form a porous three-dimensional structure including a plurality of unit cells and having predetermined geometric characteristics. Each unit cell may include a plurality of outer struts and a plurality of inner struts. Each unit cell may include a first geometric structure including a plurality of outer struts and a plurality of second geometric structures formed from a plurality of inner struts and some of the outer struts within the first geometric structure. Furthermore, the molten metal may be introduced onto the base surface as a continuous stream. The molten metal may also be introduced onto the base surface as a stream of separate molten metal droplets. In various embodiments, the type of molten metal that may be used includes, but is not limited to, titanium, titanium alloy, stainless steel, cobalt chromium alloy, tantalum, or niobium.

[0136] The first geometric structure may be a rhombic dodecahedron. In various embodiments, each of the second geometric structures may be a triangular-sided irregular polyhedron. That is, four triangular-sided irregular polyhedrons may be formed by inserting four struts into the first geometric structure. In various embodiments, an octahedron may be formed, for example, by inserting eight inner struts into the first geometric structure. That is, six octahedral geometric structures may be provided in the first geometric structure.

[0137] According to various embodiments, a method for fabricating a porous three-dimensional structure is provided, the method including applying a continuous layer of a photosensitive polymer embedded in a metal element to a base surface and photoactivating it to form a porous three-dimensional structure including a plurality of unit cells and having predetermined geometric properties. Each unit cell can include a plurality of outer struts and a plurality of inner struts. Each unit cell can include a first geometric structure including a plurality of outer struts and a plurality of second geometric structures formed from a plurality of inner struts and some of the outer struts in the first geometric structure. In various embodiments, the types of metal elements that can be used to embed the polymer material can include, but are not limited to, titanium, titanium alloys, stainless steel, cobalt chromium alloys, tantalum, or niobium.

[0138] The first geometric structure may be a rhombic dodecahedron. In some embodiments, each of the second geometric structures may be a triangular-sided irregular polyhedron. That is, four triangular-sided irregular polyhedrons may be formed by inserting four struts into the first geometric structure. In some embodiments, an octahedron may be formed, for example, by inserting eight inner struts into the first geometric structure. That is, six octahedral geometric structures may be provided in the first geometric structure.

[0139] According to various embodiments, a method for manufacturing a porous three-dimensional structure is provided, the method including depositing successive layers of metal powder and bonding with a binder material to form a porous three-dimensional structure including a plurality of unit cells and having predetermined geometric characteristics. Each unit cell may include a plurality of outer struts and a plurality of inner struts. Each unit cell may include a first geometric structure including a plurality of outer struts and a plurality of second geometric structures formed from a plurality of inner struts and some of the outer struts within the first geometric structure. In various embodiments, the types of metal powders that may be used include, but are not limited to, titanium, titanium alloy, stainless steel, cobalt chromium alloy, tantalum, or niobium powder.

[0140] The method may further include sintering the bonded metal powder with a beam. The beam (or the scanning beam) may be an electron beam. The beam (or the scanning beam) may be a laser beam.

[0141] The method may further include fusing the bonded metal powder with a beam. The beam (or the scanning beam) may be an electron beam. The beam (or the scanning beam) may be a laser beam.

[0142] The first geometric structure may be a rhombic dodecahedron. In some embodiments, each of the second geometric structures may be a triangular-sided irregular polyhedron. That is, four triangular-sided irregular polyhedrons may be formed by inserting four struts into the first geometric structure. In some embodiments, an octahedron may also be formed, for example, by inserting eight inner struts into the first geometric structure. That is, six octahedral geometric structures may be provided in the first geometric structure.

[0143] According to various embodiments, a method for manufacturing a porous three-dimensional structure is provided, the method including depositing a droplet of a metallic material on a base surface and applying heat to an area where the metallic material contacts the base surface to form a porous three-dimensional structure including a plurality of unit cells and having predetermined geometric properties. Each unit cell may include a plurality of outer struts and a plurality of inner struts. Each unit cell may include a first geometric structure including a plurality of outer struts and a plurality of second geometric structures formed from a plurality of inner struts and some of the outer struts in the first geometric structure. The beam (or scanning beam) may be an electron beam. The beam (or scanning beam) may be a laser beam. In various embodiments, types of metallic materials that may be used include, but are not limited to, titanium, titanium alloys, stainless steel, cobalt chromium alloys, tantalum, or niobium.

[0144] The deposited droplets of metallic material may be a metal slurry having embedded metallic elements. The metallic material may be a metal powder.

[0145] The first geometric structure may be a rhombic dodecahedron. In some embodiments, each of the second geometric structures may be a triangular-sided irregular polyhedron. That is, four triangular-sided irregular polyhedrons may be formed by inserting four struts into the first geometric structure. In some embodiments, an octahedron may be formed, for example, by inserting eight inner struts into the first geometric structure. That is, six octahedral geometric structures may be provided in the first geometric structure.

[0146] Although specific embodiments and applications thereof have been described herein, these embodiments and applications are merely exemplary and many variations are possible.

[0147] While the present teachings are described in conjunction with various embodiments, it is not intended that the present teachings be limited to such embodiments. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those skilled in the art.

[0148] Furthermore, in describing various embodiments, the specification may present a method and / or process as a particular sequence of steps. However, to the extent that the method or process does not depend on the particular sequence of steps described herein, the method or process should not be limited to the particular sequence of steps described. As will be appreciated by one of ordinary skill in the art, other sequences of steps may be possible. Thus, the particular sequence of steps described herein should not be construed as a limitation on the scope of the claims. Furthermore, claims directed to methods and / or processes should not be limited to performing the steps in the order written, and one of ordinary skill in the art can readily recognize that sequences can be varied and still remain within the spirit and scope of various embodiments.

[0149] [Embodiment] (1) An implantable device comprising: A porous three-dimensional structure shaped to be implanted within a patient's body, the porous three-dimensional structure comprising a plurality of interconnected organic unit cells, each organic unit cell comprising: a plurality of outer struts, each group of three outer struts intersecting to define a respective plurality of outer nodes; a plurality of inner struts, each inner strut extending from a different respective one of the outer nodes, the inner struts intersecting to define inner nodes; the plurality of outer nodes includes a first outer node defined by an intersection of a first group of three outer struts and a second outer node defined by an intersection of a second group of three outer struts; a shortest path along the strut from the first outer node to the second outer node includes only three intermediate outer nodes of the plurality of outer nodes; An implantable device, wherein a straight imaginary line extends through the first lateral node and the second lateral node, and the medial node is offset from the straight imaginary line. (2) An implantable device as described in embodiment 1, wherein each of the outer struts has a constant thickness along its entire length. (3) An implantable device as described in embodiment 1, wherein each of the inner struts has a constant thickness along its entire length. (4) An implantable device as described in embodiment 1, wherein at least one of the outer struts is curved along its length. (5) An implantable device as described in embodiment 1, wherein at least one of the inner struts is curved along its length.

[0150] (6) The implantable device of embodiment 1, wherein all of the outer struts extend along respective lengths from and to respective pairs of outer nodes, and the lengths of at least some of the outer struts are different from one another. (7) An implantable device as described in embodiment 1, wherein all of the inner and outer struts are substantially straight along their entire respective lengths. (8) The implantable device of embodiment 1, having a porosity of about 50% to about 75%. (9) The implantable device of embodiment 1, comprising a number of pores each defined by a unit cell, wherein less than 14.3 percent of the pores have a pore size less than 0.1 mm. (10) The implantable device of embodiment 9, wherein 50 percent of the pores have a pore size ranging from about 0.2 mm to about 0.7 mm.

[0151] (11) The implantable device of embodiment 10, wherein the outer struts cooperate to define a number of outer openings, the inner struts cooperate with a number of the outer struts to form a number of inner openings, the porous three-dimensional structure defines window sizes defined as diameters of circles positioned within corresponding ones of the outer and inner openings, such that each of the struts defining the outer and inner openings, respectively, are positioned on a tangent to the circle, and the implantable device includes a number of pores each defined by the unit cells, the pores defining a ratio of their respective pore size to any of their window sizes that is in the range of 1.00 to 2.90. (12) The implantable device of embodiment 1, wherein the inner node is the only inner node of the porous three-dimensional structure that is internal to the outer node. (13) An implantable device as described in embodiment 1, wherein all of the medial struts intersect at the medial node. 14. The implantable device of claim 1, wherein each organic unit cell defines a first half and a second half separated from the first half by a plane that bisects the organic unit cell structure, and wherein, for all orientations of the plane, 1) at least some of the outer nodes of the first half of the organic unit cell structure are reoriented in a first orientation relative to corresponding outer nodes of a corresponding geometric unit cell structure, and 2) at least some of the outer nodes of the second half of the organic unit cell structure are reoriented in a second orientation, different from the first orientation, relative to corresponding outer nodes of the corresponding geometric unit cell structure. (15) The implantable device of any one of embodiments 1 to 14, further comprising an organic rhombic trigonal trapezohedron having greater ductility than a corresponding geometric rhombic trigonal trapezohedron.

Claims

1. 1. An implantable device comprising: A porous three-dimensional structure shaped to be implanted within a patient's body, the porous three-dimensional structure comprising a plurality of interconnected organic unit cells, each organic unit cell comprising: a plurality of outer struts, each group of three outer struts intersecting to define a respective plurality of outer nodes; a plurality of inner struts, each inner strut extending from a different respective one of the outer nodes, the inner struts intersecting to define inner nodes; the plurality of outer nodes includes a first outer node defined by an intersection of a first group of three outer struts and a second outer node defined by an intersection of a second group of three outer struts; a shortest path along the outer strut from the first outer node to the second outer node includes only three intermediate outer nodes of the plurality of outer nodes; An implantable device, wherein a straight imaginary line extends through said first lateral node and said second lateral node, said medial node being offset from said straight imaginary line.

2. The implantable device of claim 1 , wherein each of the outer struts has a constant thickness along its entire length.

3. The implantable device of claim 1 , wherein each of the inner struts has a constant thickness along its entire length.

4. The implantable device of claim 1 , wherein at least one of the outer struts is curved along its length.

5. The implantable device of claim 1 , wherein at least one of the inner struts is curved along its length.

6. 2. The implantable device of claim 1, wherein all of the outer struts extend along respective lengths from and to respective pairs of the outer nodes, and the lengths of at least some of the outer struts differ from one another.

7. 10. The implantable device of claim 1, wherein all of said inner and outer struts are substantially straight along their entire respective lengths.

8. 10. The implantable device of claim 1 having a porosity of about 50% to about 75%.

9. 10. The implantable device of claim 1, comprising a number of pores each defined by said organic unit cells, less than 14.3 percent of said pores having a pore size less than 0.1 mm.

10. Fifty percent of the pores have a pore size ranging from about 0.2 mm to about 0.7 mm; 10. The implantable device of claim 9, wherein the outer struts cooperate to define a number of outer openings, the inner struts cooperate with a number of the outer struts to form a number of inner openings, the porous three-dimensional structure defines window sizes defined as diameters of circles positioned within corresponding said outer and inner openings, such that the outer struts and inner struts defining said outer and inner openings, respectively, are positioned on tangents to said circles, and the pores define a ratio of their respective pore size to any of their window sizes that is in the range of 1.00 to 2.90.

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