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.

An implant includes a body including a substrate and a bone interfacing lattice disposed on the substrate. The bone interfacing lattice includes at least two layers of elongate curved structural members. In addition, the at least two layers of elongate curved structural members include a first layer adjacent the substrate and a second layer adjacent the first layer. Also, the first layer has a first deformability and the second layer has a second deformability, wherein the second deformability is greater than the first deformability. Further, one or more of the elongate curved structural members may have a spiraling geometry.

An orthopaedic implant includes: an implant body having an outer surface; and a textured porous material attached to the outer surface and having a plurality of pores and a plurality of islands extending away from the outer surface, the plurality of islands being configured to shear biological tissue during implantation.

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.

An implant includes a body including a substrate and a bone interfacing lattice disposed on the substrate. The bone interfacing lattice includes at least two layers of elongate curved structural members. In addition, the at least two layers of elongate curved structural members include a first layer adjacent the substrate and a second layer adjacent the first layer. Also, the first layer has a first compressibility and the second layer has a second compressibility, wherein the second compressibility is greater than the first compressibility. Further, an interface between the first layer and the second layer is a transition region having a thickness within which the elongate curved structural members of the first layer are intermingled with the elongate curved structural members of the second layer such that a boundary of the first layer overlaps with a boundary of the second layer.

Modular bone reinforcement systems, bone plates, assembled bone reinforcements, and methods of reinforcing a bone are described. A modular bone reinforcement system includes a plurality of bone plates, each of which has a series of tabs disposed along at least one edge of the bone plate for forming a snap-fit attachment to a mating series of tabs of another bone plate of the plurality of bone plates to form an assembled bone reinforcement. A first bone plate of the plurality of bone plates has a first shape and a second bone plate of the plurality of bone plates has a second shape that is different from the first shape. The modular bone reinforcement system can include additional components, such one or more fixation devices, reduction devices, navigation aids, or other components.

In embodiments of the invention, an implant that anchors into bone may have a bone-facing region that comprises a plurality of interconnected struts. The interconnected struts may define local features such as engagement ridges, fins, crests, a macroscopic surface-interrupting feature, a divertor structure, and sawteeth in any combination. Such features may help resist translation or rotation of the implant, and may be conducive to bone ingrowth. Parameters such as local empty volume fraction and local average strut length can be varied, even within the features, by the design of the network of struts. Struts may be tapered. Cantilever struts may also be provided, which may point in a desired direction. The pattern of struts may be specified to the level of dimensions and location of individual struts. The implant may be manufactured by additive manufacturing methods. The mesh of struts may be generated by an algorithm using Voronoi tessellation.