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.

A method for forming a prosthesis comprising a bone-like portion and a cartilage-like portion can comprise additively manufacturing a first positive mold in accordance with a portion of a first three-dimensional model of a portion of a bone. A first negative mold can be formed from the first positive mold. The bone-like portion can be created within the first negative mold. A second positive mold of the bone and a cartilage can be additively manufactured from a second three-dimensional model. A portion of the second three-dimensional model can correspond to a portion of the first three-dimensional model. A second negative mold can be formed from the second positive mold. The bone-like portion can be positioned in the second negative mold so that the second negative mold and the bone-like portion can define a cartilage space that can be filled with a material to form the cartilage-like portion of the prosthesis.

An anatomically-shaped, human bone graft may be cultivated ex vivo using a bioreactor capable of perfusing large complex porous scaffolds. Scaffolds derived from image-based modeling of a target are seeded with human mesenchymal stem cells and cultivated. A bioreactor configured to house complex three-dimensional scaffold geometries provides controlled flow for perfusion of the cells. Dense uniform cellular growth can be attained throughout the entire scaffold as a result of the medium perfusion. In an embodiment, the bioreactor has a mold into which perfusion medium is pumped under pressure and multiple ports through which the medium exits the mold.

Aspects of the present disclosure include a device for forming a custom cement cast of an acetabular implant for a patient. The device includes an elongated handle, and a head coupled to a proximal end of the elongated handle. The head includes a body, a circumferential lip, and a nipple. The body of the head is shaped as a spherical cap, and includes a circular base and an apex. The circumferential lip extends radially outwardly from the circular base of the body. The nipple extends from the apex of the body in a direction perpendicular to the circular base.

The present invention includes a method for generating a three-dimensional model of a bone. The method may further include generating a cut plan for excavating a portion of the bone according to the cut plan to allow the insertion of a custom implant. In a particular arrangement, the method may includes excavating the bone with an autonomous extremity excavator utilizing the cut plan generated by a processor. In a further arrangement, the method may include generating a digital model of a custom implant and generating, using the digital model, a physical model sharing the same dimensions as the digital module using manufacturing device.

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.

The production of bioceramic powders and bioceramic implants are described and an additive manufactured implant used for tissue reconstruction and a method for manufacturing the implant are disclosed. The implant may be fabricated at least in part from suitable bioceramic powders produced using tailored mineral compositions tailored to the unique material properties of the tissue being replaced. The implants may be tailored to a three-dimensional shape and mechanical properties of the tissue defect designed to be replaced by surgical implantation of the device. Native tissue repair and regeneration at the site of implantation are also provided.

In various embodiments, an implant for interfacing with a bone structure includes a web structure including a space truss. The space truss includes two or more planar truss units having a plurality of struts joined at nodes and the web structure is configured to interface with human bone tissue. In some embodiments, a method is provided that includes accessing an intersomatic space and inserting an implant into the intersomatic space. The implant includes a web structure including a space truss. The space truss includes two or more planar truss units having a plurality of struts joined at nodes and the web structure is configured to interface with human bone tissue.

A method of preparing an interpositional implant suitable for a knee. The method includes determining a three-dimensional shape of a tibial surface of the knee. An implant is produced having a superior surface and an inferior surface, with the superior surface adapted to be positioned against a femoral condyle of the knee, and the inferior surface adapted to be positioned upon the tibial surface of the knee. The inferior surface conforms to the three-dimensional shape of the tibial surface. The implant may be inserted into the knee without making surgical cuts on the tibial surface. The tibial surface may include cartilage, or cartilage and bone.

A method of manufacturing a resorbable, macroporous bioactive glass scaffold comprising approximately 15-45% CaO, 30-70% SiO.sub.2, 0-25% Na.sub.2O, 0-17% P.sub.2O.sub.5, 0-10% MgO and 0-5% CaF.sub.2 by mass percent, produced by mixing with pore forming agents and specified heat treatments.