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.

A surgical implant may include a porous structure with interconnected pores for ingrowth of bone into the porous structure. The porous structure has an arrangement of fibres which are attached to one another, the fibres being arranged in stacked layers. The porous structure has a surface including different regions having different porosities. A method of making the above surgical implant is also described.

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.

This invention provides novel synthetic bone grafting materials or tissue engineering scaffolds with desired structural and biological properties (e.g., well-controlled macroporosities, spatially defined biological microenvironment, good handling characteristics, self-anchoring capabilities and shape memory properties) and methods of their applications in vivo.

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 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.

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 composite threaded interbody device includes (a) an outer surface that is cylindrical or conical, (b) a plastic core having two outer sections, each of the outer sections forming a respective portion of the outer surface and spanning a respective azimuthal range in an azimuthal dimension relative to a longitudinal axis of the outer surface, the outer sections being separated from each other in the azimuthal dimension by two recessed sections that are recessed from the outer surface, and (c) two threaded endplates coupled to the two recessed sections and spanning gaps between the outer sections, to complete the outer surface.