Thermal spray processing and cold spray processing are utilized to
manufacture porous starting materials (such as tube stock, wire and
substrate sheets) from biocompatible metals, metal alloys, ceramics and
polymers that may be further processed into porous medical devices, such
as stents. The spray processes are also used to form porous coatings on
consolidated biocompatible medical devices. The porous substrates and
coatings may be used as a reservoir to hold a drug or therapeutic agent
for elution in the body. The spray-formed porous substrates and coatings
may be functionally graded to allow direct control of drug elution
without an additional polymer topcoat. The spray processes are also used
to apply the drug or agent to the porous substrate or coating when drug
or agent is robust enough to withstand the temperatures and velocities of
the spray process with minimal degradation.