An orthopedic implant includes a porous insert having a first insert portion having a first insert thickness and a second insert portion having a second insert thickness. The implant includes a non-metallic structure having a first non-metallic portion having a first non-metallic thickness and a second non-metallic portion having a second non-metallic thickness. The first non-metallic portion is attached to the first insert portion and the second non-metallic portion is attached to the second insert portion. Either or both of the second insert thickness being different from the first insert thickness and the second non-metallic thickness being different from the first non-metallic thickness. The porous insert includes a porous projection extending into the non-metallic structure.

A system for additive manufacturing a medical device, the system comprising a first dispensing system, a second dispensing system, a deposition apparatus, and a deposition substrate on a surface of which the deposition apparatus is configured to deposit at least one elastomeric material into a filament. The deposition apparatus receives the at least one elastomeric material from the first and second dispensing systems in proportions effecting a desired property in the medical device. The deposition apparatus may comprise heating and/or cooling elements, a sonic vibration module, and/or a pneumatic suck-back valve. The deposition substrate may have a configuration corresponding to a desired shape of the medical device and is configured to rotate and/or translate relative to the deposition apparatus. The system comprises a controller configured to control the deposition.

A surgical implant device, including: an implant body; a porous layer disposed adjacent to the implant body, wherein the porous layer includes a lattice of intersecting struts; and a plurality of needle structures protruding from the porous layer opposite the implant body, wherein at least some of the plurality of needle structures traverse the porous layer and are anchored to the implant body. The plurality of needle structures that traverse the porous layer and are anchored to the implant body are coupled to one or more intersecting struts of the lattice. Optionally, some of the plurality of needle structures are spaced apart from the implant body and are anchored only to the porous layer. Preferably, one or more of the implant body, the porous layer, and the plurality of needle structures are formed by an additive manufacturing technique.

A lattice or solid structure for a medical device includes a first layer of first filaments discretely formed from at least one medical-grade silicone material. The first filaments are arranged in a predetermined pattern and may be directly adjacent to one another or spaced apart. Additional layers of filaments may be provided adjacent to the first layer, and chemically bonded thereto to form an integrated structure that is without interruption or with interstices therebetween.

In various embodiments, an implant for interfacing with a bone structure includes a web structure including a space truss. The space truss includes two or more planar truss units having a plurality of struts joined at nodes and the web structure is configured to interface with human bone tissue. In some embodiments, a method is provided that includes accessing an intersomatic space and inserting an implant into the intersomatic space. The implant includes a web structure including a space truss. The space truss includes two or more planar truss units having a plurality of struts joined at nodes and the web structure is configured to interface with human bone tissue.

An orthopedic assembly includes a tibial prosthesis that includes a body that defines an anterior side and a posterior side. The body further incudes a recess in the anterior side of the joint prosthesis and a plurality of openings that extend through the body from the anterior side to the posterior side thereof. At least a first and second opening of the openings are positioned at respective lateral and medial sides of a longitudinal axis of the tibial prosthesis. A modular insert is positioned within the recess of the body such that at least a portion of the modular insert is positioned between the openings of the body. The modular insert is formed separately from the tibial prosthesis and has a porous outer surface to promote tissue ingrowth.

An orthopaedic prosthetic component comprises a fixation peg including a porous three-dimensional structure configured to permit bone in-growth. The porous three-dimensional structure has an outer surface boundary. The fixation peg includes a plate attached to the porous three-dimensional structure at the outer surface boundary. The plate includes a tapered body having an outer wall that faces away from the porous three-dimensional structure and is devoid of any openings.

A surgical implant device, including: an implant body; a porous layer disposed adjacent to the implant body, wherein the porous layer includes a lattice of intersecting struts; and a plurality of needle structures protruding from the porous layer opposite the implant body, wherein at least some of the plurality of needle structures traverse the porous layer and are anchored to the implant body. The plurality of needle structures that traverse the porous layer and are anchored to the implant body are coupled to one or more intersecting struts of the lattice. Optionally, some of the plurality of needle structures are spaced apart from the implant body and are anchored only to the porous layer. Preferably, one or more of the implant body, the porous layer, and the plurality of needle structures are formed by an additive manufacturing technique.

The present invention relates to orthopaedic implants having a fenestrated hollow shell and a biologic core. These design features provide an improved interface between the implant and the surrounding tissue, aiding fixation, and provide a vehicle for applying new bone healing and enhancing modalities, such as gene therapy, tissue engineering, and growth factors.

Bone implants, including methods of use and assembly. The bone implants, which are optionally composite implants, generally include a distal anchoring region and a growth region that is proximal to the distal anchoring region. The distal anchoring region can have one or more distal surface features that adapt the distal anchoring region for anchoring into iliac bone. The growth region can have one or more growth features that adapt the growth region to facilitate at least one of bony on-growth, in-growth, or through-growth. The implants may be positioned along a posterior sacral alar-iliac (“SAI”) trajectory. The implants may be coupled to one or more bone stabilizing constructs, such as rod elements thereof.