Warsaw Orthopedic, Inc. (Warsaw, IN)

A build plate system includes an body that is able to define at least one of the cavities. The insert is designed and shaped to fit within the cavity such that the at least one cavity orients the insert to form at the very least a portion of an axis of screw thereon using a manufacturing method using an additive manufacturing device. Some embodiments provide structures, spinal constructs, and surgical instruments, and also methods.

Degenerative, degenerative, and trauma conditions can result in the spinal pathology. Most often, spinal conditions cause deformity, pain, injury to the nerve, and loss of or loss of mobility.

The conditions are treated using non-surgical techniques, such as medication, rehabilitation and exercises. But, these therapies may not work for all patients. The surgical treatment for these spinal disorders includes discectomy, correction, fusion laminectomy, implantable prosthetics and discectomy. As part of these surgical treatments, spinal constructs including bone fasteners are often used to provide stability to the area being treated. The bone fasteners were previously created using a medical machining process. This document describes an improvement on these technologies.

A build plate system may be offered in one form. The system comprises a body that defines at least one cavity. The insert is designed and shaped to fit into the at least one cavity such that the at least one cavity orients the insert to form at the very least a portion of a screw shaft thereon by a manufacturing method using an additive manufacturing apparatus. Systems, surgical instruments, methods and spinal structures in various embodiments.

A method for fabricating bone screws is described in one particular embodiment. The procedure involves the following steps: placing a build plate inside an additive manufacturing chamber, the chamber having at least 1 cavity; placing the insert inside the cavity to ensure that it is oriented for the formation of at most a portion of a screw shaft, using the additive manufacturing device according to selected configuration parameters; then making the screw shaft layer by layer.

In one embodiment an additive manufacturing apparatus is provided. An enclosure is utilized to create a working chamber and an laser device. The working chamber contains an assembly plate. The plate defining atleast one cavity. An insert sized and shaped to fit within the at least one cavity in a way that at least one cavity orients the insert in order to create at least a small portion of an elongated screw shaft by selective laser melting of an insert to create at most part of the screw shaft with a powder bed process.

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