The present invention includes a robotic system for the enhanced automation, manipulation, and control of electroprocessing in two or three dimensions. In one embodiment, the system includes a sealed chamber devoid of any electrical or conductive components which would interfere with the electrical field and eventual material fabrication, while still allowing for two-dimensional and three-dimensional robot motion. In certain embodiments, the system of the invention produces materials or scaffolds with complex shapes, including materials with ridges, valleys, curves, and the like, which are difficult or impossible to construct using traditional systems.

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 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.

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 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 expandable support device for tissue repair is disclosed. The device can be used to repair hard or soft tissue, such as bone or vertebral discs. The device can have multiple flat sides that remain flat during expansi A method of repairing tissue is also disclosed. Devices and methods for adjusting (e.g., removing, repositioning, resizing) deployed orthopedic expandable support devices are also disclosed. The expandable support devices can be engaged by an engagement device. The engagement device can longitudinally expand the expandable support device. The expandable support device can be longitudinally expanded until the expandable support device is substantially in a pre-deployed configuration. The expandable support device can be then be physically translated and/or rotated.

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.

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.

A method for texturing of selected surfaces on a spinal implant. The implant is pretreated with an EDM process by passing the implant by an electrode along an axis, at a predetermined speed, voltage and current. The implant is further conditioned by Al.sub.2O.sub.3 grit blasting followed by an acidic solution bath and process water rinse, which yields a surface porosity and topography conducive to osseointegration on the surface of the spinal implant.

A tibial baseplate for tibial component of a knee prosthesis including: a bulk solid portion including a proximally facing surface adapted to accommodate a bearing element for the articulation of a femoral component of the knee prosthesis; a plurality of porous portions integral with the bulk solid portion having a porous portion contacting surface opposite to the proximally facing surface adapted to contact a proximal tibia. Advantageously, the plurality of porous portions are seamlessly incorporated and embedded in the bulk solid portion.