This disclosure describes manufacturing of a device configured to guide bone and tissue regeneration for a bone defect. A method may include receiving a three-dimensional digital model or scan representing an anatomical feature to be repaired, generating a simulated membrane using the three-dimensional model, the simulated membrane being configured to cover the anatomical feature to be repaired, generating a digital two-dimensional flattened version of the simulated membrane, and generating code or instructions configured to cause a three-dimensional printer or milling device to produce a trimming guide that includes an opening corresponding to the flattened version of the simulated membrane and that further includes a cut-out configured to hold a premanufactured membrane. The trimming guide may be operative as a guide for marking or cutting the premanufactured membrane through the opening while the premanufactured membrane is held in the cut-out.

A system for converting a first joint prosthesis to a second joint prosthesis in-situ includes a plurality of inserts having a bone interface side and a component facing side and a plurality of articulating components having a cavity configured to receive at least one of the plurality of inserts. The plurality of inserts may be unicompartmental, bicompartmental, or tricompartmental. The inserts may be made of metal and may have a bone contacting surface made of a porous metal. The plurality of articulating components may be unicompartmental, bicompartmental, or tricompartmental. The articulating components may be sized and shaped to cover one or more of the plurality of bone interface components and span a distance therebetween. The articulating components may be made of a polymer.

The present disclosure provides zirconium powder particles comprising pure zirconium powder particles with an oxide layer ranging from 0.05 to 5 microns in thickness and/or zirconium alloy powder particles with an oxide layer ranging from 0.05 to 5 microns in thickness. In some embodiments, the zirconium powder particles may be spherical particles, the zirconium powder particles may range from 5 microns to 125 microns in diameter, and/or the zirconium powder particles may have a median particle size ranging from 25 to 70 microns in diameter. The present disclosure further provides methods of producing medical implants or medical implant components by a process that comprises selectively applying energy to such zirconium powder particles to build the medical implants or the medical implant components. In some embodiments, the methods comprise repeatedly forming a layer of zirconium powder particles and irradiating the layer of zirconium powder particles with an energy source.

A prosthesis for implantation in a de-nucleated intervertebral disc includes a fiber ring-like layer which encloses a polymeric layer to create an annular space. The annular space is inflatable with an in-situ curable liquid polymer and forms an interior cavity. The annular space may be expanded uniformly or differentially to be tailored to the needs of a particular vertebral segment and to achieve optimal disc space width and angle, thereby stabilizing the segment while preserving normal motion of the vertebral segment. The interior cavity provides a void that allows inward deformation of the implant during weight bearing activities and bending. The prosthesis can be elastically deformed through axial elongation to a reduced profile to load into a delivery cannula using pulling techniques.

An orthopaedic prosthesis includes a femoral component comprising polymeric materials. The polymeric materials may include a polyaromatic ether or a polyacetal. The orthopaedic prosthesis may include a component having an articular layer and a support layer adjacent the articular layer. The support layer may include a reinforcement fiber. The orthopaedic prosthesis may be a knee prosthesis.

The present invention relates to the diagnosis and treatment of joint-related diseases, in particular osteoarthritis. Based on the analysis of the microarchitecture, such as microchannels, of the subchondral bone, the present invention provides methods for evaluating the health state of a joint as well as determining whether a joint is prone to develop or has already developed a disease correlated to joint and cartilage destruction. The invention further provides for membranes and other implants mimicking healthy subchondral bone structure suitable for promoting regeneration of joint structure and function.

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.

Computer implemented methods of producing a bone graft are provided. These methods include obtaining a 3-D image of an intended bone graft site; generating a 3-D digital model of the bone graft based on the 3-D image of the intended bone graft site, the 3-D digital model of the bone graft being configured to fit within a 3-D digital model of the intended bone graft site; storing the 3-D digital model on a database coupled to a processor, the processor having instructions for retrieving the stored 3-D digital model of the bone graft and for combining a carrier material with, in or on a bone material based on the stored 3-D digital model and for instructing a 3-D printer to produce the bone graft. A layered 3-D printed bone graft prepared by the computer implemented method is also provided.

A prosthetic hip joint implant comprises an acetabular liner having an acetabular liner inner surface and defining an acetabular recess, and a femoral component comprising a head having a head outer surface and defining a head recess, a shaft having a shaft proximal end and a shaft distal end disposed within the head recess, and a covering disposed on and fixedly secured to the head outer surface, the shaft distal end, head, and covering disposed within the acetabular liner recess such that the covering is in continuous contact with the acetabular liner inner surface. Polyaxial movement of the shaft distal end produces movement of the covering along the acetabular liner inner surface within the acetabular liner recess without producing relative movement between the covering and the head.

An acetabular shell component includes a solid substrate, a porous outer layer coupled to the solid substrate, a porous inner layer coupled to the solid substrate, and an inner bearing coupled to the porous inner layer. One or more adjuncts extend outward from the porous outer layer. Each adjunct includes an outer surface that defines a customized patient-specific negative contour shaped to conform to a positive contour of a patient's bone. A method for manufacturing the acetabular shell component using an additive manufacturing process is also disclosed.