Patent ID: 7537664

Claim:
A method of producing a three-dimensional porous tissue ingrowth structure comprising: depositing a first layer of a powder made from a metal selected from the group consisting of titanium, titanium alloys, stainless steel, cobalt chrome alloys, tantalum and niobium, onto a substrate; scanning a laser beam at least once over said first layer of metal powder to remelt the metal powder in order to create at least two solid lines, said laser beam having a power (P) in Joule per sec. with a scanning speed (v) in millimeters per sec., and a line separation (d) in millimeters such that the number calculated by the formula P/(d×v) lies between the range 0.3-8 J/mm 2 , so as to give a required pore size; depositing at least one layer of said powder onto said first layer; and repeating said laser scanning steps for each successive layer until a desired height is reached.