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.

Bone implant compositions and methods are provide that have a first surface and a second surface, the first surface and the second surface comprising a demineralized bone matrix and having a plurality of perforations configured to receive demineralized bone; and a third surface of the bone implant comprising cortical bone, the third surface disposed between the first surface and the second surface. The bone implant compositions and methods provided are osteoinductive and allow rapid bone fusion.

A method of forming a composite titanium body for use in forming spinal implant interbodies includes selecting a metal alloy body, carving out a top portion and a bottom portion from the metal alloy body, and bonding a porous material to the carved-out top and bottom portions. Multiple pieces may be cut from the composite titanium body, each having a front face formed of the metal alloy, top and bottom portions formed of the porous material, and with a medial portion of the metal alloy extending from the front face to the back. Methods and devices for spinal interbodies having locking mechanisms to prevent bone screw back-out are also described.

A composite interbody device includes (a) a plastic core having a superior surface and an inferior surface, (b) a superior endplate and (c) an inferior endplate. Each of the superior and inferior endplates includes (i) a bone interface side for interfacing with bone and having a plurality of pores permitting bone growth therein, and (ii) a core interface side, opposite the bone interface side, having a plurality of voids that accommodate material of the plastic core to couple the endplate to a respective one of the superior and inferior surfaces, wherein the voids are isolated from the pores to prevent the material of the plastic core from entering the pores.

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

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 a composite titanium body for use in forming spinal implant interbodies includes selecting a metal alloy body, carving out a top portion and a bottom portion from the metal alloy body, and bonding a porous material to the carved-out top and bottom portions. Multiple pieces may be cut from the composite titanium body, each having a front face formed of the metal alloy, top and bottom portions formed of the porous material, and with a medial portion of the metal alloy extending from the front face to the back. Methods and devices for spinal interbodies having locking mechanisms to prevent bone screw back-out are also described.

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

An implant providing for both short and long term stability and fixation is disclosed. The implant includes a plurality of projections extending from a bone contacting surface, and a porous material covering at least portions of the surface and projections. The orientation of the projections and the porous material provide for the stability and fixation. Methods of forming and utilizing the implant are also disclosed.

A vertebral body spacer of the present invention is used by being inserted between a vertebral body and a vertebral body (intervertebral space). The vertebral body spacer has a block body constituted of titanium or a titanium alloy as a main component thereof, and provided with a pair of contact surfaces to be made contact with the vertebral body and the vertebral body. The block body includes dense sheets having a dense part on at least a surface thereof and porous sheets having a porous part on at least a surface thereof. The porous part has a larger porosity than a porosity of the dense part. Each of the porous sheets is sandwiched between the pair of dense sheets. According to the present invention, it is possible to maintain an appropriate size between the vertebral bodies (intervertebral space).