Patent ID: 9364896
Filing Date: 2016-06-14
CPC Classification: B22D,B22F,B29C,B33Y,C22C,Y02P

Claim Text:
1. A method comprising: causing an Electron Beam Melting (EBM) manufacturing system to perform a fabrication process that results in an implantable medical device of unitary construction having a solid volume and a porous volume and wherein the fabrication process comprises carrying out the following steps on a layer-by-layer basis: spreading a layer of metal powder across a build platform of the EBM manufacturing system; selectively heating a plurality of portions of the layer of metal powder in accordance each portion's association with the solid volume or the porous volume by scanning the layer of metal powder with an electron beam of the EBM manufacturing system and adjusting a power of the electron beam and a speed of said scanning; lowering the build platform based on a predetermined layer thickness; wherein the solid volume comprises a main body of the implantable medical device and wherein the porous volume comprises an outer layer of the implantable medical device to encourage bone ingrowth after implantation; wherein the porous volume comprises a replicated pattern of a predefined unit cell structure; wherein the predefined unit cell structure includes a plurality of pores formed by a plurality of interconnected struts; and wherein the plurality of pores include triangle-shaped pores and decagon-shaped pores.