Porous biocompatible structures suitable for use as medical implants and methods for fabricating such structures are disclosed. The disclosed structures may be fabricated using rapid manufacturing techniques. The disclosed porous structures each have a plurality of struts and nodes where no more than two struts intersect one another to form a node. Further, the nodes can be straight, curved, and can include portions that are curved and/or straight. The struts and nodes can form cells that can be fused or sintered to at least one other cell to form a continuous reticulated structure for improved strength while providing the porosity needed for tissue and cell in-growth.

A system and method for improving upon an ability of a surgeon to repair traumatic bone injury using new materials, components, and structures. A structure may be used as an implant or a component of an external fixator for a fractured long bone with that structure having anisotropic and viscoelastic properties, such as through additive manufacturing techniques.

A spinal implant includes a base and a coating film disposed on the base and including a calcium phosphate-based material and an antimicrobial agent. A surface of the base includes a first region in which the coating film is disposed and a second region exposed from the coating film.

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 plurality of orthopedic implant components is provided. The method includes providing a design for a first implant component having at least one dimension that is based on patient-specific information and a design for a second implant component having at least one dimension that is based on patient specific information. A build plan is created that includes a position and orientation for at least each of the first and second implant components within a build chamber of a solid freeform fabrication machine and with respect to a platform of the build chamber. The implants included in the build plan are produced by executing a build run of the solid freeform fabrication machine based on the build plan, wherein the plurality of implant components are positioned and oriented in an interleaved build configuration according to the build plan.

Disclosed herein are methods and devices for repairing articular surfaces. The articular surface repairs are customizable or highly selectable by patient and geared toward providing optimal fit and function.