A method of making a light weight component is provided. The method including the steps of: forming a metallic foam core into a desired configuration; and applying an external metallic shell to an exterior surface of the metallic foam core after it has been formed into the desired configuration.

A joint prosthesis system is suitable for cementless fixation. The system has two metal implant components and a bearing. One of the metal implant components has an articulation surface for articulation with the bearing. The other metal implant component has a mounting surface for supporting the bearing. One of the metal implant components 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.

This method for producing porous sintered aluminum includes: mixing aluminum powder with a sintering aid powder containing titanium to obtain a raw aluminum mixed powder; mixing the raw aluminum mixed powder with a water-soluble resin binder, water, and a plasticizer containing at least one selected from polyhydric alcohols, ethers, and esters to obtain a viscous composition; drying the viscous composition in a state where air bubbles are mixed therein to obtain a formed object prior to sintering; and heating the formed object prior to sintering in a non-oxidizing atmosphere, wherein when a temperature at which the raw aluminum mixed powder starts to melt is expressed as Tm (° C.), a temperature T (° C.) of the heating fulfills Tm−10 (° C.)≤T≤685 (° C.).

Provided herein are methods of preparing a metal foam that include the steps of forming a metal foam precursor with a slurry comprising a metal component, a dispersant, a binder and an antisolvent, and sintering the metal foam precursor. Such methods may provide metal foams having various pore sizes. Methods further include forming a thin metal foam on a base material.

Processes for tailoring the macroscopic shape, metallic composition, mechanical properties, and pore structure of nanoporous metal foams prepared through combustion synthesis via direct write 3D printing of metal energetic ligand precursor inks made with water and an organic thickening agent are disclosed. Such processes enable production of never before obtainable metal structures with hierarchical porosity, tailorable from the millimeter size regime to the nanometer size regime. Structures produced by these processes have numerous applications including, but not limited to, catalysts, heat exchangers, low density structural materials, biomedical implants, hydrogen storage medium, fuel cells, and batteries.

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.

Foamable semifinished product (1) in the form of granules produced from the metal alloy and the foam agent is inserted into the cavity of the closable mould (2) and the liquid (3) with the density that is higher than the apparent (or bulk) density of the resulting foam is led to it. The liquid has a temperature which is higher than the temperature of the melting of the metal alloy; the transfer of the heat to the particles of the foamable semifinished product (1) takes place; it subsequently expands, whereby it is supported by the liquid (3). During the expansion at least part of the liquid (3) is pushed by the expansion itself out of the mould (2) through the opening. The liquid (3) allows the regulation of the pressure of the environment of the foam agent, too, which helps to set exactly the moment of expansion. The metal melt can be advantageously used as liquid (3). The melt can partially remain in the mould (2) so the hybrid structure of the component is created. The new method makes the foaming significantly quicker, it secures the homogeneity of the metal foam, simplifies the moulds and diminishes the energy demands for the whole process.

Foamable semifinished product (1) in the form of granules produced from the metal alloy and the foam agent is inserted into the cavity of the closable mould (2) and the liquid (3) with the density that is higher than the apparent (or bulk) density of the resulting foam is led to it. The liquid has a temperature which is higher than the temperature of the melting of the metal alloy; the transfer of the heat to the particles of the foamable semifinished product (1) takes place; it subsequently expands, whereby it is supported by the liquid (3). During the expansion at least part of the liquid (3) is pushed by the expansion itself out of the mould (2) through the opening. The liquid (3) allows the regulation of the pressure of the environment of the foam agent, too, which helps to set exactly the moment of expansion. The metal melt can be advantageously used as liquid (3). The melt can partially remain in the mould (2) so the hybrid structure of the component is created. The new method makes the foaming significantly quicker, it secures the homogeneity of the metal foam, simplifies the moulds and diminishes the energy demands for the whole process.

A device including a first portion made of a first material and a second portion made of a second material, the second part extends from one of faces of the first portion and is made of an amorphous material.

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.