The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

Systems, methods, and compositions disclosed herein provide for low-oxygen metal powders. These metal powders, such as very-fine powders and spherical powders of titanium and titanium alloys, can be effectively deoxidized through use of vapor deoxidation without requiring the powder to undergo re-sizing or re-shaping subsequent to the deoxidation. Systems, methods, and compositions in accordance with the present disclosure can produce low-cost, low-oxygen, metal powders, such as very-fine powders and spherical powders of, for example, titanium and titanium alloys. Moreover, systems, methods, and compositions in accordance with the present disclosure can provide for reducing the number of processes or cost of processes required to produce these low-oxygen metal powders.

The present disclosure relates to an iron-chromium-aluminum (Fe—Cr—Al) powder suitable for additive manufacturing and to an additive manufacturing process. The present disclosure also relates to an additive manufactured object.

A joint prosthesis system is suitable for cementless fixation. The system includes a metal implant component that has a mounting surface for supporting an insert. The metal implant component includes a solid metal portion and a porous metal portion. The porous metal portion has surfaces with different characteristics, such as roughness, to improve bone fixation, ease removal of the implant component in a revision surgery, reduce soft tissue irritation, improve the strength of a sintered bond between the solid and porous metal portions, or reduce or eliminate the possibility of blood traveling through the porous metal portion into the joint space. A method of making the joint prosthesis is also disclosed. The invention may also be applied to discrete porous metal implant components, such as augment.

Some variations provide a system for producing a functionalized powder, comprising: an agitated pressure vessel; first particles and second particles contained within the agitated pressure vessel; a fluid contained within the agitated pressure vessel; an exhaust line for releasing the fluid from the agitated pressure vessel; and a means for recovering a functionalized powder containing the second particles disposed onto surfaces of the first particles. A preferred fluid is carbon dioxide in liquefied or supercritical form. The carbon dioxide may be initially loaded into the pressure vessel as solid carbon dioxide. The pressure vessel may be batch or continuous and is operated under reaction conditions to functionalize the first particles with the second particles, thereby producing a functionalized powder, such as nanofunctionalized metal particles in which nanoparticles act as grain refiners for a component ultimately produced from the nanofunctionalized metal particles. Methods for making the functionalized powder are also disclosed.

The present disclosure discloses a zonal trabecular uni-compartmental femoral condylar component containing zirconium-niobium alloy on oxidation layer and preparation method, including following steps: using zirconium niobium alloy powder as raw material, conducting a 3D printing for one-piece molding to obtain an intermediate product of the uni-compartmental femoral condylar component, performing hot isostatic pressing and cryogenic oxidation to obtain the uni-compartmental femoral condylar component; the uni-compartmental femoral condylar component includes an articular surface and an osseointegration surface, a bone trabeculae is arranged on the osseointegration surface. The present invention can reduce the fretting wear of the interface between the prosthesis and the bone, and reduce the stress shielding effect of the prosthesis on the bone tissue, homogenize the stress of the femoral condylar bone tissue, and improve the initial stability and long-term stability of the uni-compartmental femoral condylar component.

Method for manufacturing an aluminium alloy part by additive manufacturing comprising a step during which a layer of a mixture of powders is locally melted and then solidified, characterised in that the mixture of powders comprises: first particles comprising at least 80% by mass of aluminium and up to 20% by mass of one or more additional elements, and second yttria-stabilized zirconia particles, the mixture of powders comprising at least 1.5% by volume of second particles.

A method of titanium rod additive manufacturing may comprise: mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend; isostatic pressing the powder blend to form a billet having a cross-sectional profile; cutting the billet to form a rod feedstock having the first cross-sectional profile; loading the rod feedstock into an additive manufacturing machine configured to deposit the rod feedstock; and producing a metallic component from the rod feedstock.

An optical mount part having a body that includes a composite of a titanium-zirconium-niobium alloy. The titanium-niobium-zirconium alloy includes titanium, about 13.5 to about 14.5 wt. % zirconium, and about 18 to about 19 weight % (wt. %) niobium. The titanium-niobium-zirconium alloy has a congruent melting temperature of about 1750 to about 1800° Celsius (° C.).

The invention provides a method for the recovery of a metal-containing product (M.sub.Prod) comprising: providing a composite material comprising a matrix of oxidised reductant (R.sub.O), a product metal (M.sub.P) dispersed in the matrix of oxidised reductant (R.sub.O), and one or more metal compounds (M.sub.PC.sub.R) of the product metal (Mp) in one or more oxidation states dispersed in the matrix of oxidised reductant (R.sub.O); and treating the composite material to at least partially remove the one or more metal compounds (M.sub.PC.sub.R) from the matrix of oxidised reductant (R.sub.O) to form the metal-containing product (M.sub.Prod).