A method for forming a thermoplastic body having regions with varied material composition and/or porosity. Powder blends comprising a thermoplastic polymer, a sacrificial porogen and an inorganic reinforcement or filler are molded to form complementary parts with closely toleranced mating surfaces. The parts are formed discretely, assembled and compression molded to provide a unitary article that is free from discernible boundaries between the assembled parts. Each part in the assembly has differences in composition and/or porosity, and the assembly has accurate physical features throughout the sections of the formed article, without distortion and nonuniformities caused by variable compaction and densification rates in methods that involve compression molding powder blends in a single step.

A method for forming a thermoplastic body having regions with varied material composition and/or porosity. Powder blends comprising a thermoplastic polymer, a sacrificial porogen and an inorganic reinforcement or filler are molded to form complementary parts with closely toleranced mating surfaces. The parts are formed discretely, assembled and compression molded to provide a unitary article that is free from discernible boundaries between the assembled parts. Each part in the assembly has differences in composition and/or porosity, and the assembly has accurate physical features throughout the sections of the formed article, without distortion and nonuniformities caused by variable compaction and densification rates in methods that involve compression molding powder blends in a single step.

The present patent application is directed to compositions and shaped structures implantable into mammalian bodies, the compositions and shaped structures having localized bioactive surfaces.

The present patent application is directed to compositions and shaped structures implantable into mammalian bodies, the compositions and shaped structures having localized bioactive surfaces.

A composite material for use, for example, as an orthopedic implant, that includes a porous reinforced composite scaffold that includes a polymer, reinforcement particles distributed throughout the polymer, and a substantially continuously interconnected plurality of pores that are distributed throughout the polymer, each of the pores in the plurality of pores defined by voids interconnected by struts, each pore void having a size within a range from about 10 to 500 μm. The porous reinforced composite scaffold has a scaffold volume that includes a material volume defined by the polymer and the reinforcement particles, and a pore volume defined by the plurality of pores. The reinforcement particles are both embedded within the polymer and exposed on the struts within the pore voids. The polymer may be a polyaryletherketone polymer and the reinforcement particles may be anisometric calcium phosphate particles.

A composite material for use, for example, as an orthopedic implant, that includes a porous reinforced composite scaffold that includes a polymer, reinforcement particles distributed throughout the polymer, and a substantially continuously interconnected plurality of pores that are distributed throughout the polymer, each of the pores in the plurality of pores defined by voids interconnected by struts, each pore void having a size within a range from about 10 to 500 μm. The porous reinforced composite scaffold has a scaffold volume that includes a material volume defined by the polymer and the reinforcement particles, and a pore volume defined by the plurality of pores. The reinforcement particles are both embedded within the polymer and exposed on the struts within the pore voids. The polymer may be a polyaryletherketone polymer and the reinforcement particles may be anisometric calcium phosphate particles.

Provided herein are settable surgical compositions and methods for their intraoperative use.

Provided herein are settable surgical compositions and methods for their intraoperative use.

A method of forming a scaffold is disclosed herein. In some embodiments, a method of forming a scaffold includes dissolving a polymer in a solvent to form a polymer solution; adding additive precipitating agent to the polymer solution; precipitating and expanding the polymer from the polymer solution to form a scaffold; and removing the solvent from the scaffold. In some embodiments, prior to adding the precipitating agent, the method further comprising adding at least one of calcium phosphate or a bioactive additive to the polymer solution to form a mixture including the polymer solution and the at least one of calcium phosphate or bioactive additive.

A method of forming a scaffold is disclosed herein. In some embodiments, a method of forming a scaffold includes dissolving a polymer in a solvent to form a polymer solution; adding additive precipitating agent to the polymer solution; precipitating and expanding the polymer from the polymer solution to form a scaffold; and removing the solvent from the scaffold. In some embodiments, prior to adding the precipitating agent, the method further comprising adding at least one of calcium phosphate or a bioactive additive to the polymer solution to form a mixture including the polymer solution and the at least one of calcium phosphate or bioactive additive.