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.

The present disclosure provides alert implants that comprise a medical device and an implantable reporting processor (IRP), where one example of such a medical device includes a component for a total knee arthroplasty (TKA) such as a tibial extension, a femoral component for hip replacements, a breast implant, a distal rod for arm or leg breakage repair, a scoliosis rod, a dynamic hip screw, a spinal interbody spacer, and tooling and methods that may be used to form the alert implant, and uses of such alert implants in the health maintenance of patients who receive the implant.

An implant removal tool (1) used to remove a femoral implant (17) from a femur bone (18) by providing a substantially U-shaped body (2) having a substantially rectangular-shaped opening (9) located thereon that allows the substantially U-shaped body to be placed over a neck (21) of a femoral implant so a sharpened front edge (5) of the substantially U-shaped body makes direct contact with an inner surface of the stein of the femoral implant. The U-shaped body may have front side edges (26, 27) that extend beyond a front edge (5) to allow the front side edges to cut anterior and posterior surface of the implant.

A system for facilitating arthroplasty procedures includes a robotic device, a reaming tool configured to interface with the robotic device, and a processing circuit communicable with the robotic device. The processing circuit is configured to obtain a surgical plan comprising a first planned position of an implant cup and a second planned position of an implant augment relative to a bone of a patient, determine a planned bone modification configured to prepare the bone to receive the implant cup in the first planned position and the implant augment in the second planned position, generate one or more virtual objects based on the planned bone modification, control the robotic device to constrain the cutting tool with the one or more virtual objects while the cutting tool interfaces with the robotic device and is operated to modify the bone in accordance with the planned bone modification.

An intramedullary stem prosthesis includes a trunnion tapered in a first direction toward a proximal end of the intramedullary stem, and a conical shaft interfacing with the trunnion at a modular taper junction. The conical shaft is tapered in a second direction toward a distal end of the second component and has a proximal portion, a distal portion, and flutes positioned about a longitudinal axis of the conical shaft and extending along an entire length of the conical shaft and terminating at the modular taper junction such that the flutes intersect the modular taper junction. The proximal portion defines a first taper angle, the distal portion defines a second taper angle greater than the first taper angle, and the flutes define a major diameter of the conical shaft. The major diameter tapers at a major diameter taper angle that is constant along the entire length of the conical shaft.

An acetabular implant can include a predetermined force deflection curve as described herein. The implant can provide individual layers to achieve the predetermined force deflection curve. The acetabular implant can be manufactured using additive manufacturing techniques to achieve the required structures that provide the predetermined force deflection curve.

The invention relates to a connecting sleeve for anchoring shafts of two oppositely arranged prostheses, preferably on an elongate bone such as a femur or humerus. The reinforcing sleeve comprises two receiving bushes (1, 2) for one prosthesis shaft each and comprises a separable coupling region (3) arranged therebetween for connection in such a manner as to resist shear forces and rotation. According to the invention, each receiving bush (1, 2) has, on the side thereof facing the coupling region, one fork (31, 32) of a pair of forks that interact with each other, and a fitting block (4) is arranged on a base of the fork, the lateral surfaces (44) of which fitting block have a distance that corresponds to an inner width of the fork, and the lateral surfaces (44) are designed to contact flanks of the fork in a planar manner, at least one fastening screw (5) being arranged transversely through the fork. The fork connection is simpler to produce than the known wedge connection and yet is sufficiently robust. Unlike in the case of the wedge connection, an exact fit is not required; a clearance fit between the fork (31, 32) and the fitting block (4) is sufficient in principle, excessive play being eliminated by means of the fastening screw (5).

Described is a femoral component of a prosthetic hip implant. The femoral component can include: a neck portion; and a stem portion including a proximal end and a distal end. The neck portion extends from the proximal end, and the stem portion comprises a first solid portion and at least one additional portion including at least one of a hollow portion, a porous portion, and a second solid portion comprised of a different solid material from a solid material of the first solid portion. The first solid portion and the at least one additional portion are in a predetermined configuration. The femoral component comprises a unitary component that is formed by additive manufacturing of the femoral component from a 3D model of the femoral component.

A device, for example a medical implant, and a method of making the same, the device having a metal or metal alloy substrate, for example cobalt chrome, and a diffusion hardened metallic surface, for example a plasma carburized surface, contacting a non-diffusion hardened surface or a diffusion hardened surface having a diffusion hardening species different from that of the opposing surface.

A femoral prosthesis system for an orthopaedic hip implant and method of use is disclosed. The prosthesis system includes a femoral stem component that includes a core body and a casing that encases the core body. The casing can be additively manufactured such that the core body defines a predetermined orientation in the core body among a plurality of permissible predetermined orientations. The femoral stem component can further include a neck and a trunnion that extends from the neck. The neck can extend out with respect to the core body at a predetermined angle within a range of permissible predetermined angles.