This invention relates generally to spine surgery and, in particular, to a surgical implant for separating adjacent spinal vertebrae.

An exemplary process includes determining a desired pore size, selecting an initial pore size greater than the target pore size, manufacturing a porous structure with the initial pore size, forging the porous structure to form a forged part having the desired pore size, and forming an orthopedic device from the forged part.

An orthopaedic implant includes an implant body having a first surface, a second surface opposite the first surface, and a cavity formed therein that extends through the first surface and the second surface. The implant body has a third surface with at least one first opening formed therethrough to the cavity. The at least one first opening includes an outer portion having an outer diameter and an inner portion having an inner diameter. The implant includes a load bearing member including a porous material held within the cavity. The outer portion of the at least one first opening is configured to couple to a tool for receiving, from the tool, a material agent, and the inner portion of the at least one first opening is configured to couple to a plug for preventing the material agent from exiting the porous material via the at least one first opening.

A method of forming an orthopaedic implant includes: heat bonding a porous material to a surface of an insert to form a bonded insert; placing a bare portion of the bonded insert in an opening formed in a material of an implant body; and heat bonding the bare portion to the material to bond the bonded insert to the implant body.

A method of forming an orthopaedic implant includes: placing a bonding portion of a mating part in an opening formed in an implant body, the opening defining a variable opening width; and heat bonding the bonding portion to the material to bond the mating part to the implant body.

An orthopaedic implant includes: a base including a molding material; a first porous ingrowth material region coupled to the base; a second porous ingrowth material region coupled to the base; and at least one barrier insert coupled to the base, the barrier insert including a barrier material that is configured to prevent introduction of the molding material of the base into some pores of the first porous ingrowth material region and some pores of the second porous ingrowth material region during molding of the base.

There are provided herein methods and products resulting therefrom. The methods include attaching a pre-fabricated porous ingrowth structure to a substrate by applying heat, or creating and bonding an in-situ-formed porous ingrowth structure from beads on a substrate by applying heat. In some embodiments, an oxidized metal surface of the substrate is diffusion hardened during the heating process. In some embodiments, a vacuum is applied during the heating process. In some embodiments, pressure is applied during the heating process. Also provided herein are assemblies for compressing the pre-fabricated porous ingrowth structure or the beads onto the substrate during the heating process.

An exemplary process includes determining a desired pore size, selecting an initial pore size greater than the target pore size, manufacturing a porous structure with the initial pore size, forging the porous structure to form a forged part having the desired pore size, and forming an orthopedic device from the forged part.

A composite threaded interbody device includes (a) an outer surface that is cylindrical or conical, (b) a plastic core having two outer sections, each of the outer sections forming a respective portion of the outer surface and spanning a respective azimuthal range in an azimuthal dimension relative to a longitudinal axis of the outer surface, the outer sections being separated from each other in the azimuthal dimension by two recessed sections that are recessed from the outer surface, and (c) two threaded endplates coupled to the two recessed sections and spanning gaps between the outer sections, to complete the outer surface.

An exemplary process includes determining a desired pore size, selecting an initial pore size greater than the target pore size, manufacturing a porous structure with the initial pore size, forging the porous structure to form a forged part having the desired pore size, and forming an orthopedic device from the forged part.