The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

The present disclosure in one aspect provides a surgical implant comprising an upper bone contacting surface comprising a plurality of irregularly shaped pores having an average pore size, where the pores are formed by a plurality of struts, a lower bone contacting surface comprising a plurality of irregularly shaped pores having an average pore size, wherein the pores are formed by a plurality of struts; and a central body comprising a plurality of irregularly shaped pores having an average pore size, wherein the pores are formed by a plurality of struts, wherein the average pore size on the upper and lower bone contacting surfaces is different than the average pore size on the central body.

A modular augment cone system and methods of implanting the modular augment cone system. The system includes a main body cone a first cutout in the cone wall, and including a proximal end, a distal end, and a cone wall extending between the proximal and distal ends. A portion of the cone wall proximal to the first cutout includes an attachment feature. A first augment cone is positionable in the first cutout, the first augment cone including an attachment feature configured to mate with the attachment feature of the cone wall to attach the first augment cone into the first cutout. The main body cone can include a second cutout in the cone wall. In such systems, the modular augment cone system can include a second augment cone configured to mate with an attachment feature of the cone wall to attach the second augment cone into the second cutout.

A femoral prosthesis system for an orthopaedic hip implant and method of use is disclosed. The prosthesis system includes a femoral stem component that includes a core body and a casing that encases the core body. The casing can be additively manufactured such that the core body defines a predetermined orientation in the core body among a plurality of permissible predetermined orientations. The femoral stem component can further include a neck and a trunnion that extends from the neck. The neck can extend out with respect to the core body at a predetermined angle within a range of permissible predetermined angles.

In one embodiment, the present disclosure relates to a broach for use in a mammalian femur. The broach includes a body with a proximal portion and a distal portion extending from the proximal portion. The proximal portion has a first surface with a plurality of first teeth and the distal portion has a second surface with a plurality of second teeth. Each of the second teeth is different from each of the first teeth. And, each of the plurality of second teeth include pointed protrusions extending outward from the second surface.

A tibial implant may include a plurality of geometrically conformal implant subunits. The implant subunits may be configured for individual insertion within a wedge-shaped-void of the tibia. The implant subunits may further be configured for assembly in order to provide an implant substantially covering an exposed portion of cortical bone formed when performing a surgical osteotomy. In some embodiments, some or all of the plurality of subunits may be mechanically interlocked with each other. Methods and kits for insertion and assembly of implants are further described.

A self-seating spinal cervical cage, including a pair of spaced support members, each respective support member having a first end and a second end, a plurality of teeth extending from each respective first end and each respective second end, a plate member bisecting each respective spaced support member, an array of apertures formed through the plate member, and a porous scaffolding operationally connected to the plate member and defining an open cell pore network. The plate member bisects the porous scaffolding. The plate member and the spaced support members define a unitary titanium body.

An expandable augment system is provided for use with an acetabular cup. The expandable augment system can include an expandable augment module that is adjustable in size and that can be adjusted incrementally between a fully collapsed state and an expanded state. A first portion of the expandable augment module is attachable to an outer surface of an acetabular cup and a second portion of the expandable augment module is attachable to bone or to a fixed augment module (e.g., a fixed angle augment module) that is attached to bone and interposed between the adjustable augment module and bone.

Augment element for knee prosthesis, comprising a metal body of a substantially truncated conical shape configured to be inserted into a bone extremity and having an outer surface comprising a metal trabecular surface. The metal body being hollow with an axial through-cavity defining a plurality of substantially annular transversal sections. The metal body is inclined in a direction of inclination, so as to define at least one eccentricity between a first transversal section at a first end of the axial through-cavity and a second transversal section at a second end of the axial through-cavity. The augment element further comprises a plurality of through-slits in the metal body, open from the first end up to an intermediate portion on the metal body, wherein the plurality of through-slits is configured for a radial compression of the metal body, locally reducing a circumference of the substantially annular transversal sections during insertion of the augment element, and increasing a press-fit towards a bone portion.

An orthopedic implant can comprise a structural body, a plug and a frangible connection. The structural body can comprise a first surface, a second surface opposing the first surface, and a through-bore extending from the first surface to the second surface. The through-bore can have a bore surface. The structural body can be formed of a porous material. The plug can be disposed in the through-bore. The frangible connection can link the bore surface and the plug. A method of manufacturing an orthopedic implant can comprise producing a porous structural body having a port, producing a plug for positioning in the port, and producing a plurality of frangible crosspieces within the port to connect the plug to the structural body.