An interbody spacer for spinal fusion surgery includes first and second opposite side walls that have open-cell metal foam at upper and lower faces, and a three-dimensional lattice disposed between open-cell metal foam at the upper and lower faces. The open-cell metal foam is in communication with the three-dimensional lattice so that bone growth can enter the three-dimensional lattice from the open-cell metal foam. The interbody spacer may be formed by additive manufacturing.

Methods of making medical devices are described. An example device is an implant used in spaces between vertebrae in a vertebral column of an animal. The example medical device includes a main body that has a lengthwise axis, a proximal end, a distal end, a length that extends from the proximal end to the distal end, an upper wall, a lower wall, a first lateral wall, a second lateral wall, and defines a plurality of pockets, a plurality of pocket supports, an interior chamber, a plurality of windows, and a recess. A pocket support of the plurality of pocket supports is disposed within each pocket of the plurality of pockets. A first mask includes an elongate member and a plurality of projections and is integrally formed with the medical device main body. The mask is used for performing a finishing process on the device and subsequently removed using a tool.

An intervertebral implant with a support portion (1.1) and a proximal contact portion (1.3) adjoined thereto in the longitudinal direction, is better adapted, as an intervertebral implant, to the contours of the lower and upper sides of the vertebrae that are spaced apart by the implant. An upper side (1.6) and a lower side (1.7) of the implant are configured symmetrically relative to a horizontal center plane (L-Q). In particular a height of the support portion between the transition (U) thereof to the contact portion (1.3) and a distal end face (1.2) facing away from the contact portion (1.3) are greater than the height at the transition (U) and at the distal end face (1.2).

An intervertebral cage with an outer frame, an open inner core region and a porosity gradient within the outer frame is provided. The outer frame includes a posterior wall, an anterior wall, a pair of side walls extending between the posterior wall and the anterior wall and the porosity gradient may comprise at least one of: a decreasing average pore diameter in a direction from an outer surface to an inner surface of at least one of the pair of side walls; an increasing average pore diameter in a direction from an outer surface to an inner surface of at least one of the pair of side walls; a decreasing average pore diameter in a direction from an upper surface to a lower surface of at least one of the side walls; and an increasing average pore diameter in a direction from an upper surface to a lower surface of at least one of the side walls.

An intervertebral implant for being implanted between adjacent vertebrae is provided. The implant includes a generally elongate implant body having a length extending between opposite longitudinal ends thereof, a superior face and an inferior face. The superior face and inferior face include cortical teeth adjacent to the implant body longitudinal ends. Additionally, the superior and inferior faces include longitudinally central teeth intermediate the cortical teeth and have bone engaging ends. The central teeth have a sharper configuration than that of the cortical teeth bone engaging ends for biting into the softer central bone material of the vertebrae. The cortical teeth are arranged in a first density per unit area and the central teeth are arranged in a second density per unit area that is less than the first density.

A method of manufacturing an intervertebral implant comprising forming the implant with at least one dimension that is greater than a desired dimension, the implant comprising a superior bone facing surface, an inferior bone facing surface, a distal side, a proximal side, and lateral sides; coating at least the superior bone facing surface and the inferior bone facing surface with an osteophilic material; and machining one or more of the distal side, proximal side and lateral sides to the desired dimensions after coating; wherein edges of the coating on the superior bone facing surface and the inferior bone facing surface are machined to be flush with the distal side, proximal side and/or lateral sides.

An intervertebral cage with an outer frame, an open inner core region and a porosity gradient within the outer frame is provided. The outer frame includes a posterior wall, an anterior wall, a pair of side walls extending between the posterior wall and the anterior wall and the porosity gradient may comprise at least one of: a decreasing average pore diameter in a direction from an outer surface to an inner surface of at least one of the pair of side walls; an increasing average pore diameter in a direction from an outer surface to an inner surface of at least one of the pair of side walls; a decreasing average pore diameter in a direction from an upper surface to a lower surface of at least one of the side walls; and an increasing average pore diameter in a direction from an upper surface to a lower surface of at least one of the side walls.

A build-plate with integrally-formed spinal implant constructs and a method used in forming spinal implant constructs on the build plate and machining the spinal implant constructs formed on the build plate to manufacture spinal implants is provided. The spinal implant constructs can be formed via additive manufacturing processes by adding material to an upper surface of the build plate, and then the spinal implant constructs can be subjected to subtractive manufacturing processes to form the spinal implants.

An intervertebral implant for being implanted between adjacent vertebrae is provided. The implant includes a generally elongate implant body having a length extending between opposite longitudinal ends thereof, a superior face and an inferior face. The superior face and inferior face include cortical teeth adjacent to the implant body longitudinal ends. Additionally, the superior and inferior faces include longitudinally central teeth intermediate the cortical teeth and have bone engaging ends. The central teeth have a sharper configuration than that of the cortical teeth bone engaging ends for biting into the softer central bone material of the vertebrae. The cortical teeth are arranged in a first density per unit area and the central teeth are arranged in a second density per unit area that is less than the first density.

An intervertebral implant with a support portion (1.1) and a proximal contact portion (1.3) adjoined thereto in the longitudinal direction, is better adapted, as an intervertebral implant, to the contours of the lower and upper sides of the vertebrae that are spaced apart by the implant. An upper side (1.6) and a lower side (1.7) of the implant are configured symmetrically relative to a horizontal center plane (L-Q). In particular a height of the support portion between the transition (U) thereof to the contact portion (1.3) and a distal end face (1.2) facing away from the contact portion (1.3) are greater than the height at the transition (U) and at the distal end face (1.2).