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.

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 method of manufacturing a composite interbody device includes assembling superior and inferior endplates, this including forming or layering micro-porous titanium on opposing sides of a solid titanium sheet. A first of the opposing sides provides a micro-porous bone interface layer and a second of the opposing sides provides a micro-porous core interface side. The solid titanium sheet therebetween forms a central barrier layer. The inferior and superior endplates are placed in a mold, on each side of a core cavity, with the core interface sides facing the core cavity and the bone interface sides facing away from the cavity. Molten plastic is injection-molded into the core cavity to form a plastic core between the endplates, the molten plastic extruding into pores of the microporous core interface sides. The plastic is set to bond the core with the endplates.

The present invention provides a porous composite the connected structure, method and prosthetic implant for sensor detection and drug delivery, where the porous structure is pre-connected or integrally formed with an intermediate to obtain a composite, which is connected to the substrate so that the porous structure covers the surface of the substrate. The present invention realizes the effective connection of a porous structure and a substrate, satisfying the connection requirements when the overall properties of the mechanical structure and its surface properties differ, and avoids the problem that the mechanical properties of the substrate could be greatly reduced by processes such as hot pressing. The connected structure of the present invention is provided with at least one holding space in which sensors can be placed to detect the status of the interior and exterior of the connected structure as needed, and in which drugs can also be placed and released according to the need for prevention or treatment, broadening the application scopes of the connected structure.

A method for attaching a porous metal layer to a dense metal substrate, wherein the method is particularly useful in forming orthopedic implants such as femoral knee components, femoral hip components, and/or acetabular cups. The method, in one embodiment thereof, comprises providing a solid metal substrate; providing a porous metal structure; contouring a surface of the porous metal structure; placing the porous structure against the substrate such that the contoured surface of the porous metal structure is disposed against the substrate, thereby forming an assembly; applying heat and pressure to the assembly in conjunction with thermal expansion of the substrate in order to metallurgically bond the porous structure and the substrate; and removing mass from the substrate after the porous structure is bonded to the substrate, thereby finish processing the assembly.

A metal implant for use in a surgical procedure is provided with a surface layer that is integral with the metal substrate, and which incorporates a biocidal material. The surface layer may be grown from the metal substrate, by anodising, and the biocidal material incorporated in it by ion exchange. Alternatively the layer may be deposited by electroplating, followed by diffusion bonding so as to become integral with the metal substrate. In either case, silver is a suitable biocidal material; and both the release rate and the quantity of biocidal material should be low to avoid toxic effects on body cells. Electropolishing the surface before formation of the surface layer is also beneficial, and this may be achieved by electropolishing.

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 needle parts formed into a needle shape having both end portions and a porous part having through holes passing through the porous part in a thickness direction thereof, and a porosity of at least a surface of the porous part is larger than a porosity of each of the needle parts. The needle parts are inserted into the through holes so that the both end portions are projected from the contact surfaces.

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.

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.