A bone implant includes a body having a porous structure and having a size and shape configured for fitting to a bone, preferably in a bone defect. The porous structure is comprised of regularly arranged elementary cells whose interior spaces form interconnected pores, the elementary cells are formed by basic elements arranged in layers, wherein the basic elements are shaped like tetrapods, the tetrapods in each layer being arranged in parallel orientation and being positioned in-layer rotated with respect to tetrapods of an adjacent layer. The layers with rotated and non-rotated tetrapods are alternatingly arranged. Thereby a porous structure can be achieved which features improved mechanical characteristics, leading to improved biocompatibility.

A bone implant includes a body having a porous structure and having a size and shape configured for fitting to a bone, preferably in a bone defect. The porous structure is comprised of regularly arranged elementary cells whose interior spaces form interconnected pores, the elementary cells are formed by basic elements arranged in layers, wherein the basic elements are shaped like tetrapods, the tetrapods in each layer being arranged in parallel orientation and being positioned in-layer rotated with respect to tetrapods of an adjacent layer. The layers with rotated and non-rotated tetrapods are alternatingly arranged. Thereby a porous structure can be achieved which features improved mechanical characteristics, leading to improved biocompatibility.

Provided is a method for producing a sliding member formed by impregnating a porous base member made of a bronze-based alloy with a resin material, the sliding member including a sliding surface where both the porous base member and the resin material are exposed, the method including: a step of preparing a back metal layer; a porous base member formation step of forming the porous base member by depositing particles of the bronze-based alloy on a surface of the back metal layer and sintering the particles; an impregnation step of impregnating the porous base member with the resin material; a deformation step of deforming an end edge of the back metal layer in a direction away from the sliding surface; and a cutting step of cutting the porous base member impregnated with the resin material to form the sliding surface.

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.

The invention relates to a three-dimensional screen printing method for producing a green part from printing material for a powder metallurgical component, wherein the printing material contains a fraction of powder, more particularly metal powder or ceramic powder, and binder or consists of these materials, characterized in that a screen printing mask has a screen printing structure having openings for pressing the printing material through, the openings being partly undulate so that the green part at least partly has a three-dimensional undulate structure and/or undulate edges.

Anode and cathode electrodes of a rechargeable lithium-ion battery are manufactured using metal foam. This lithium-ion battery with the metal-foam electrodes can have pores coated or filled, or both, with high-capacity active materials for greater energy density, better safety, improved power, and longer cycle life. Aluminum (or nickel) and copper metal-foam electrodes are manufactured using space-holder and freeze-casting methods. An anode can be filled with a graphite or silicon slurry, or a combination. A cathode can be filled with a lithium cobalt oxide (or other higher-capacity active materials) slurry. The relatively thick metal-foam electrodes are attached to the cell, separated by a separator, and wetted by an electrolyte, forming a high-capacity secondary battery. The battery will have higher density, improved power, and good cycle life.

Anode and cathode electrodes of a rechargeable lithium-ion battery are manufactured using metal foam. This lithium-ion battery with the metal-foam electrodes can have pores coated or filled, or both, with high-capacity active materials for greater energy density, better safety, improved power, and longer cycle life. Aluminum (or nickel) and copper metal-foam electrodes are manufactured using space-holder and freeze-casting methods. An anode can be filled with a graphite or silicon slurry, or a combination. A cathode can be filled with a lithium cobalt oxide (or other higher-capacity active materials) slurry. The relatively thick metal-foam electrodes are attached to the cell, separated by a separator, and wetted by an electrolyte, forming a high-capacity secondary battery. The battery will have higher density, improved power, and good cycle life.

Disclosed are methods of making porous zinc electrodes. Taken together, the steps are: forming a mixture of water, a soluble compound that increases the viscosity of the mixture, an insoluble porogen, and metallic zinc powder; placing the mixture in a mold to form a sponge; optionally drying the sponge; placing the sponge in a metal mesh positioned to allow air flow through substantially all the openings in the mesh; heating the sponge in an inert atmosphere at a peak temperature of 200 to 420° C. to fuse the zinc particles to each other to form a sintered sponge; and heating the sintered sponge in an oxygen-containing atmosphere at a peak temperature of 420 to 700° C. to form ZnO on the surfaces of the sintered sponge. The heating steps burn out the porogen.

Disclosed are methods of making porous zinc electrodes. Taken together, the steps are: forming a mixture of water, a soluble compound that increases the viscosity of the mixture, an insoluble porogen, and metallic zinc powder; placing the mixture in a mold to form a sponge; optionally drying the sponge; placing the sponge in a metal mesh positioned to allow air flow through substantially all the openings in the mesh; heating the sponge in an inert atmosphere at a peak temperature of 200 to 420° C. to fuse the zinc particles to each other to form a sintered sponge; and heating the sintered sponge in an oxygen-containing atmosphere at a peak temperature of 420 to 700° C. to form ZnO on the surfaces of the sintered sponge. The heating steps burn out the porogen.

A method of impregnating voids of a sintered metal body having a porous structure with resin, the method comprising preparing a resin material that contains a defoamer containing hydrophilic or hydrophobic particles, defoaming the prepared resin material by reducing pressure of the resin material, applying the defoamed resin material onto a surface of the sintered metal body, impregnating the voids with the resin material by reducing pressure of the sintered metal body and the resin material applied to the surface of the sintered metal body so as to expel gas from the voids; and curing the resin material by heating.