Devices and methods for orthopedic support are disclosed. The device can have a first rigid section hingedly attached to a second rigid section. The device can be curved or rotated around obstructions along an access path to a target site. The device can be delivered to an intervertebral location in a patient.

Devices to repair bone defects prevent the formation of depressions and palpable tissue at bone repair sites. The devices can be used to repair burr holes in the cranium, providing an improved cosmetic result that reduces or eliminates functional handicaps that can result from combing and hairdressing. The devices are secured in bone defects with filament elements, by expanding the device inside the bone defect, or by gluing. Tissue in-growth into the device regenerates bone at the defect site, and prevents the formation of depressions or palpable tissue. The devices preferably comprise a ceramic and poly-4-hydroxybutyrate or copolymer thereof, or a ceramic and poly(butylene succinate) or copolymer thereof.

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.

A device for containing bone graft material includes an outer sleeve including a first proximal longitudinal split extending along a length thereof and a first distal longitudinal split extending along a length thereof and an inner sleeve connected to the outer sleeve via at least one strut so that a bone graft collecting space is defined therebetween, the inner sleeve including a second distal longitudinal split extending along a length thereof in combination with an interstitial mesh extending circumferentially between the inner and outer sleeves to hold graft material in the bone graft collecting space, the interstitial mesh including a third longitudinal split extending along a length thereof so that a distal side of the device may be spread open to open the distal longitudinal slot from the outer sleeve, through the interstitial mesh and the inner sleeve to a space radially within the inner sleeve.

Novel articles of manufacture based comprising lattices based on trabecular bone, having a plurality of plates and interconnecting rods. The trabecular bone-inspired lattice may be designed based on the general alignment of plates and rods found in trabecular bone, including anisotropic lattices having one or more predominant axes of mechanical strength. Lumbar fusion implants and other implants are provided having a trabecular bone inspired lattice in which bone graft material may be packed and providing a scaffold for bone fusion and growth. The implants may be based on bone structures having a predominant axis of mechanical strength and may be deployed in sites with the predominant axis of mechanical strength aligned with the primary axis of mechanical stress, such as in the the spine.

According to one embodiment of the disclosure, an implant includes a body having a surface with a flexible pattern defined by a plurality of material segments including a first material segment and a second material segment. The first material segment abuts the second material segment. Further, the first material segment includes a first non-linear shape extending between a first end and a second end while the second material segment includes a second non-linear shape extending between a first end and a second end. The two material segments are interconnected such that one of the first end and the second end of the first non-linear shape is interconnected with one of the first end and the second end of the second non-linear shape.

A method of forming an implant having a porous tissue ingrowth structure and a bearing support structure. The method includes depositing a first layer of a metal powder onto a substrate, scanning a laser beam over the powder so as to sinter the metal powder at predetermined locations, depositing at least one layer of the metal powder onto the first layer and repeating the scanning of the laser beam.

A method of forming an implant having a porous tissue ingrowth structure and a bearing support structure. The method includes depositing a first layer of a metal powder onto a substrate, scanning a laser beam over the powder so as to sinter the metal powder at predetermined locations, depositing at least one layer of the metal powder onto the first layer and repeating the scanning of the laser beam.

A three-dimensional structure is formed when layers of a material are deposited onto a substrate and scanned with a high energy beam to at least partially melt each layer of the material. Upon scanning the layers at predetermined locations at least a first segment overlapping a second segment and underlapping a third segment is formed.

A three-dimensional structure is formed when layers of a material are deposited onto a substrate and scanned with a high energy beam to at least partially melt each layer of the material. Upon scanning the layers at predetermined locations at least a first segment overlapping a second segment and underlapping a third segment is formed.