ADDITIVE MANUFACTURED DENTAL IMPLANTS AND METHODS THEREOF
20210153982 · 2021-05-27
Inventors
- James D. Wernle (Warsaw, IN, US)
- Esther Moran (Greem Acres, FL, US)
- Elnaz Ajami (Palm Beach Gardens, FL, US)
- Hai Bo Wen (Lake Worth, FL, US)
- Cong Fu (Palm Beach Gardens, FL, US)
Cpc classification
A61C2008/0046
HUMAN NECESSITIES
International classification
Abstract
A monolithic dental implant formed from an additive manufacturing method can include a non-porous portion and a porous structure. The porous structure can increase osseointegration of the dental implant and increase the secondary stability.
Claims
1. A monolithic dental implant, comprising: a non-porous head portion at a coronal end of the implant, the non-porous head portion having an interior portion extending apically from the head portion; a non-porous apical portion at an apical end of the implant; and a porous middle portion positioned between the non-porous head portion and the non-porous apical portion, the porous middle section including a porous structure, wherein the non-porous head portion, the non-porous apical portion, and the porous middle section are integral with each other and formed via an additive manufacturing method.
2. The monolithic dental implant of claim 1, wherein at least one of the non-porous head portion, the non-porous apical portion, and the porous middle portion includes a thread.
3. The monolithic dental implant of claim 1, wherein at least one of the non-porous head portion, the non-porous apical portion, and the porous middle section the treatment includes at least one of: threads, annular grooves, surface recesses, and a biocompatible coating.
4. The monolithic dental implant of claim 1, wherein a cross-section of the porous section includes a non-porous core.
5. The monolithic dental implant of claim 1, wherein a cross-section of the porous section includes one or more reinforcement members.
6. The monolithic dental implant of claim 5, wherein the reinforcement members extend from the non-porous head portion to the non-porous apical portion.
7. The monolithic dental implant of claim 1, wherein the porous middle section includes at least one thread, the thread including a root region, a flank region, and a crest region.
8. The monolithic dental implant of claim 7, wherein the crest region and a portion of the flank region are non-porous
9. The monolithic dental implant of claim 7, wherein a porosity of the thread extending from the root region to the crest region is non-uniform.
10. The monolithic dental implant of claim 9, wherein a porosity of the crest region of the thread is greater than a porosity of root region.
11. A method of forming a monolithic dental implant, comprising: using an additive manufacturing technique to form the monolithic dental implant including: a non-porous head portion at a coronal end of the implant, the non-porous head portion having an interior portion extending apically from the head portion; a non-porous apical portion at an apical end of the implant; and a porous middle portion positioned between the non-porous head portion and the non-porous apical portion, the porous middle section including a porous structure, wherein the non-porous head portion, the non-porous apical portion, and the porous middle section are integral with each other.
12. The method of claim 11, wherein the additive manufacturing technique is selected laser melting additive manufacturing.
13. The method of claim 11, wherein the additive manufacturing technique is laser metal deposition additive manufacturing
14. The method of claim 11, wherein the additive manufacturing technique is electron beam additive manufacturing.
15. The method of claim 11, wherein the porous middle section includes a non-porous section and a porous structure.
16. The method of claim 11, further including: machining at least one of the non-porous head portion, the non-porous apical portion, and the porous middle portion to form threads on the at least one of the non-porous head portion, the non-porous apical portion, and the porous middle portion.
17. The method of claim 11, further including: machining a portion of the non-porous head portion to include the abutment connection geometry.
18. A monolithic dental implant, comprising: a non-porous head portion at a coronal end of the implant, the non-porous head portion having an interior portion extending apically from the head portion; a non-porous apical portion at an apical end of the implant; and a porous middle portion positioned between the non-porous head portion and the non-porous apical portion, the porous middle portion including non-porous section and a porous structure, wherein the non-porous head portion, the non-porous apical portion, and the porous middle portion are integral with each other and formed via an additive manufacturing method.
19. The monolithic dental implant of claim 18, wherein the non-porous section of the middle porous portion includes at least one reinforcement member extending within the porous structure from the non-porous head portion to the non-porous apical portion.
20. The monolithic dental implant of claim 18, wherein the non-porous section of the middle porous portion includes at least one threaded reinforcement member forming a portion of an external surface and extending from the non-porous head portion to the non-porous apical portion.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the various embodiments of the present disclosure, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying figures, in which:
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DETAILED DESCRIPTION
[0034] Referring to
[0035] The materials used to produce the implant can be metallic, plastic, inorganic or composite. The surface finish for each part can be either machined only or treated. The surface treatments include, but are not limited to, grit blasting, acid etching, anodization, chemical deposition, and physical deposition. The goals of the surface treatments include enhancing osteointegration, improving soft tissue attachment and reducing bacteria colonization. The cervical portion 12 is illustrated as being solid; however, the cervical portion 12 can be solid, porous, or a hybrid of the two. The porous/solid ratio in the cervical portion 12 can be custom designed based on patient's conditions.
[0036] In an example where the cervical portion 12 includes threads, the threads can be either produced by the additive manufacturing process or machined after the additive manufacturing process forms the integral unit including the porous and non-porous portions.
[0037] The middle section 14 can be completely porous or partially porous and include a non-porous section and a porous structure. The porous/solid ratio in the middle portion 14 can be custom designed based on the patient's conditions. The porous middle section 14 can be tailored to achieve a design including a porous structure including threads, e.g., that follow the same thread pattern of the rest of the implant for easy insertion, while having the porous ingrowth surface. As discussed herein, if the porous middle section has threads, the threads can either be produced via the additive manufacturing process or by machining.
[0038] The structure of the apical section 16 can be solid, porous, or a hybrid. The porous/solid ratio in the apical section 16 can be custom designed based on the patient's conditions. Similar to the other sections, the threads on the apical section 16 can be produced by the additive manufacturing process or machined after the additive manufacturing.
[0039] The implant/abutment connection geometry 18, can include, but is not limited to, internal connections, external connections, screw-less connections, and a one-piece dental implant with abutment integrally formed with the dental implant 10.
[0040] Besides dental implants, the additive manufacturing methods mentioned in this disclosure can also be used to produce scaffold, healing abutments, definitive abutments, surgical tools, etc.
[0041] The implant 10 in
[0042] As seen in
[0043] The porous middle section 34 includes a porous structure 40 that bone can grow into to improve long term stability of the implant device. Such a porous structure 40 may also increase short term stability for immediate loading because of its large friction coefficient with surrounding bone. In one example, the porosity of the porous structure 40 is substantially constant (i.e., substantially uniform) within the middle section 34. In one example, the porosity of the porous structure 40 changes as you move axially along the longitudinal axis. For example, the porosity of the porous structure 40 toward the cervical section 32 can be less than the porosity of the porous structure 40 toward the apical section 36. In one example, the porosity of the porous structure 40 toward the cervical section 32 can be greater than the porosity of the porous structure 40 toward the apical section 36. In a further example, the porosity of the porous structure 40 can be determined based on patient specific factors such that the porosity is non-uniform throughout the porous structure 40.
[0044] In additional to changing porosity along the longitudinal axis, the porosity within the porous structure can change in a direction perpendicular to the longitudinal axis. That is, the porosity of the porous structure can increase or decrease as you move from the longitudinal axis towards the external surface. In one example, the external surface can have a lower porosity to increase the durability of the external surface for implantation and the inner portion (closest to the longitudinal axis) of the porous structure 40 can have a greater porosity.
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[0046] In
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[0050] While the sections 41, 43, 44, 45, and 46 discussed in
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[0053] The root region 62 can be flat, curved, or connected at a point. The crest region 66 can be flat, pointed, or curved. The flank region 64 can be flat or curved. As seen in
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[0055] In the example shown in
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[0060] In some examples, the dental implants including porous and non-porous structures can be a formed from a titanium alloy. In one example, the porous sections of the additive manufacturing process can use an additive manufacturing process, such as with OsseoTi™, which is commercially available from Zimmer Biomet, of Warsaw, Ind. The porous sections can be highly biocompatible, have high corrosion resistance and includes a highly interconnected porous architecture that mimics the porous structure of human cancellous bone, which can enhance bone integration and in-growth. In one exemplary implementation, the porous structures can include a porosity of 70%. The porous structures formed can be formed using a three-dimensional model of cancellous bone material as a template. The template can then be utilized to form any three-dimensionally printable structure, such as the porous structure of dental implant, discussed herein.
[0061] In examples, dental implants can be formed with one or more of a variety of materials including but not limited to polymeric materials which are subsequently pyrolyzed, metals, metal alloys, ceramics. In some instances, dental implant can be a fabricated using a selective laser sintering (SLS) or other additive manufacturing-type process such as direct metal laser sintering. In one example, implant is produced in layer-wise fashion from a laser-fusible powder, e.g., a polymeric material powder or a metal powder, that is deposited one layer at a time. The powder is fused, remelted or sintered, by the application of laser energy, or energy from another source, that is directed to portions of the powder layer corresponding to a cross section of the article. After the fusing of the powder in each layer, an additional layer of powder is deposited, and a further fusing step is carried out, with fused portions or lateral layers fusing so as to fuse portions of previous laid layers until a three-dimensional article is complete. In certain embodiments, a laser selectively fuses powdered material by scanning cross-sections generated from a 3-D digital description of the article, e.g., from a CAD file or scan data, on the surface of a powder bed. Net shape and near net shape constructs are infiltrated and coated in some instances. Unfused material can be removed from the completed component. Other types of rapid manufacturing processes can be used to fabricate the interbody implant, such as 3D printing processes. For example, the dental implants disclosed herein can use rapid prototype equipment. It is contemplated that many rapid prototyping techniques may be utilized with the present invention such as: stereolithography, laminated-object manufacturing, selective laser sintering, solid ground curing, or other known rapid prototyping processes.
[0062] In one example, a single monolithic dental implant including an abutment can be formed using the additive manufacturing methods disclosed herein. A patient specific abutment can be designed and formed with the dental implant.
[0063] The additive manufacturing methods disclosed herein allow for complex geometries to be created, while maintaining the structural integrity and not requiring complex coupling mechanisms to couple porous and non-porous sections together. As discussed herein, the porous structure can increase the osseointegration and secondary stability of the implant and is particularly suited for contacting bone and/or soft tissue. In this regard, the porous structure having a three-dimensional porous structure, or any region thereof, may be fabricated to virtually any desired density, porosity, pore shape, and pore size (e.g., pore diameter). Such structures therefore can be isotropic or anisotropic.
[0064] Such porous structures can be infiltrated and coated with one or more coating materials. When coated with one or more biocompatible metals, any suitable metal may be used including any of those disclosed herein such as tantalum, titanium, a titanium alloy, cobalt chromium, cobalt chromium molybdenum, tantalum, a tantalum alloy, niobium, or alloys of tantalum and niobium with one another or with other metals. In various examples, a three-dimensional porous structure may be fabricated to have a substantial porosity, density, pore shape and/or void (pore) size throughout, or to comprise at least one of pore shape, pore size, porosity, and/or density being varied within the structure. For example, a three-dimensional porous structure to be infiltrated and coated may have a different pore shape, pore size and/or porosity at different regions, layers, and surfaces of the structure.
[0065] The dental implants can include a non-porous or essentially non-porous portion and can provide foundation upon which a three-dimensional porous structure will be built and fused thereto using a selective laser sintering (SLS) or other additive manufacturing-type process.
[0066] The rapid manufacturing processes can be used to include a desired level of porosity directly into porous structure. Likewise, lattice structures can be made to have any desired shape, size, number and aggregate strength and density in order to generate sufficient bonding strength to survive implantation and operation of porous structure, while permitting infusion of bone from lattice structures to promote osseointegration.
[0067] The porous structures described herein can have sufficient strength to support the forces during insertion. However, the greater the porosity of the structures, the weaker the porous structure becomes. Thus, the porous structure can have varying porosity to increase the strength and/or include reinforcement members as disclosed herein.
VARIOUS NOTES & EXAMPLES
[0068] The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventor also contemplates examples in which only those elements shown or described are provided. Moreover, the present inventor also contemplates examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.
[0069] In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.
[0070] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.
[0071] Method examples described herein can be machine or computer-implemented at least in part Some examples can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, in an example, the code can be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of these tangible computer-readable media can include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.
[0072] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.