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.

Summary A golf club face member is made by a manufacturing process, such as 3D printing, for a complex topology that is sturdy with good CT. 3D printing creates a face in which struts, a lattice-like structure, a waffle-iron pattern, or interior voids provide great strength and low mass. A golf club head has a club head body defining a heel portion and a toe portion and a hosel extending upward from the heel portion when the club head is at address. A face member is disposed between the heel portion and the toe portion such that it faces forward when the club head is at address. At least portion of the face member comprises a 3D printed material such as a 3D printed or sintered metal.

A body armor for protecting a part of body against a projectile, the body armor comprising an outer surface, an inner surface, and a plurality of cavities. The inner surface is shaped to fit over the protected body part, and the cavities reduce the armor weight. Additionally the cavities profile can help in stopping projectiles.

A method for manufacturing an external component for horology or jewellery made of a composite material including a reinforcement formed of a preferably perforated structure and a matrix composed of a synthetic material, the method including the successive steps consisting in: a) making a 3D file of the reinforcement, b) forming the reinforcement by additive manufacturing, c) embedding all or part of the reinforcement in the synthetic material. An external component for horology or jewellery can be made of a composite material including a matrix composed of a synthetic material and a reinforcement having a perforated structure obtained by additive manufacturing.

A spacecraft panel includes a first skin, a second skin spaced apart from the first skin, and a first truss structure connecting the first skin to the second skin. The first truss structure includes a plurality of truss members, and each truss member is integral with the first skin and the second skin, such that the first skin, the second skin, and the first truss structure collectively form a single monolithic joint-free structure.

Disclosed is a method for forming an orthopaedic implant. The method comprises determining one or more parameters of a bone, of a subject, to which the implant is to be attached, and calculating specifications based on parameters. That calculation includes calculating a mechanical property relating to elasticity of the implant, a length of the implant, and positions of two or more fixation locations by which to fix the implant to the bone. The method further comprises forming the implant based on the specifications, wherein each fixation location comprises a longitudinal axis through the implant, and calculating specifications comprises calculating a trajectory for the longitudinal axis of the respective fixation location.

The biocompatible lattice structures and implants disclosed herein have an increased or optimized lucency, even when constructed from a metallic material. The lattice structures can also provide an increased or optimized lucency in a material that is not generally considered to be radiolucent. Lucency can include disparity, maximum variation in lucency properties across a structure, or dispersion, minimum variation in lucency properties across a structure. The implants and lattice structures disclosed herein may be optimized for disparity or dispersion in any desired direction. A desired direction with respect to lucency can include the anticipated x-ray viewing direction of an implant in the expected implantation orientation.

The biocompatible lattice structures and implants disclosed herein have an increased or optimized lucency, even when constructed from a metallic material. The lattice structures can also provide an increased or optimized lucency in a material that is not generally considered to be radiolucent. Lucency can include disparity, maximum variation in lucency properties across a structure, or dispersion, minimum variation in lucency properties across a structure. The implants and lattice structures disclosed herein may be optimized for disparity or dispersion in any desired direction. A desired direction with respect to lucency can include the anticipated x-ray viewing direction of an implant in the expected implantation orientation.

A novel process for creating porous structures via powder bed fusion additive manufacturing is provided. The process reduces the computational requirement for generation of the porous structure geometry and for processing the porous structure geometry to generate CNC code. The process provides reduced file size for CNC code and avoids large files which may exceed capacity of manufacturing machines. The process also significantly reduces the time required to sinter the porous structure on a powder bed fusion manufacturing machine.

A method of manufacturing a pump inlet housing and filter for a pump assembly, wherein the pump inlet housing and filter are monolithic, the method has the steps of: defining a pump inlet housing as a housing tubular shape with an inlet aperture boundary at a housing top end, and an outlet aperture boundary at a housing bottom end; defining a lattice filter between the inlet and outlet aperture boundaries; and performing an additive manufacturing (AM) process to additively manufacture the pump inlet housing and the lattice filter such that the lattice filter is integral with the pump inlet housing.