A composite interbody device includes (a) a plastic core having a superior surface and an inferior surface, (b) a superior endplate and (c) an inferior endplate. Each of the superior and inferior endplates includes (i) a bone interface side for interfacing with bone and having a plurality of pores permitting bone growth therein, and (ii) a core interface side, opposite the bone interface side, having a plurality of voids that accommodate material of the plastic core to couple the endplate to a respective one of the superior and inferior surfaces, wherein the voids are isolated from the pores to prevent the material of the plastic core from entering the pores.

Disclosed herein is an orthopedic implant device comprising a porous structure, approximating the shape of a bone, and having modulus of elasticity similar to that of said bone. Further disclosed herein is a method of treating injuries or diseases affecting bones or muscles comprising providing an orthopedic implant device, wherein the orthopedic implant device comprising a porous structure, approximating the shape of a bone, and having a modulus of elasticity similar to that of bone, and using the orthopedic implant device to treat injuries and diseases affecting bones and muscles in a mammal. Further disclosed herein is a method of manufacturing an orthopedic implant device using an additive manufacturing method comprising the steps: (a) providing a 3-dimensional model of the orthopedic implant device; (b) inputting the 3-dimensional model to an additive manufacturing device; and (c) using the additive manufacturing device to manufacture the orthopedic implant device.

The present invention involves a system and methods for assembling and implanting a vertebral body implant. The vertebral body implant includes, but is not necessarily limited to, an expandable core body and endplates that can be attached at both ends. Endplates of various shapes, sizes and angles are attachable to the expandable core so that a suitable vertebral body implant can be implanted between vertebrae.

An intervertebral prosthesis or disk prosthesis comprising a front side, a rear side, an upper side which can be placed on the base plate of vertebral body, a lower side which can be placed on the base plate of a vertebral body, a right side, a left side, a cavity which can receive a fluid hydraulic osteocementum, an opening in the cavity and several outlets out from the cavity. The total of the transversal surfaces of the outlets S.sub.V on the front side, the total of the transversal surfaces of the outlets S.sub.H on the rear side, the total of the transversal surfaces of the outlets S.sub.R on the right side and the total of the transversal surfaces of the outlets on the left side satisfy the following conditions: S.sub.L>S.sub.R or S.sub.R>S.sub.L or S.sub.H>S.sub.V or S.sub.V>S.sub.H.

A composite interbody device for use with spinal fusion surgery is described herein. The composite interbody device comprises a central body made from a radiolucent biocompatible polymer (e.g., PEEK or UHMWPE) and metallic plates, which are placed at the superior and inferior surfaces of the central body. The metallic plates are comprised of an end plate that is adjacent to a vertebral body and an intermediate plate that is adjacent to the central body. The end plates may have one or more arrays of apertures to facilitate bone growth into the end plates to secure the interbody device within the intervertebral space. The intermediate plates may also have one or more arrays of apertures to allow the central body to bond to the end plates through compression molding, injection molding, and/or heat molding. The arrays of apertures in the end plates are not aligned with the arrays of apertures in the intermediate plates so that polymer material of the central body will not penetrate into the end plate, where bone growth is encouraged, and vice versa.

A method of manufacturing a composite interbody device includes assembling superior and inferior endplates, this including forming or layering micro-porous titanium on opposing sides of a solid titanium sheet. A first of the opposing sides provides a micro-porous bone interface layer and a second of the opposing sides provides a micro-porous core interface side. The solid titanium sheet therebetween forms a central barrier layer. The inferior and superior endplates are placed in a mold, on each side of a core cavity, with the core interface sides facing the core cavity and the bone interface sides facing away from the cavity. Molten plastic is injection-molded into the core cavity to form a plastic core between the endplates, the molten plastic extruding into pores of the microporous core interface sides. The plastic is set to bond the core with the endplates.

The present invention involves a system and methods for assembling and implanting a vertebral body implant. The vertebral body implant includes, but is not necessarily limited to, an expandable core body and endplates that can be attached at both ends. Endplates of various shapes, sizes and angles are attachable to the expandable core in a plurality of positions so that a suitable vertebral body implant can be implanted between vertebrae from an anterior, anterior-lateral, lateral, posterior or posterior-lateral approach.

A system includes and implant and an elongate device. The implant includes a first bone engaging portion and a flexible portion coupled to an end of the first bone engaging portion at an engagement portion. The flexible portion is configured to be compressed toward a longitudinal axis defined by the flexible portion. The elongate device includes an engagement end that is sized and configured to engage the engagement portion of the implant.

Tissue spacer implants and surgical methods for inserting the implants are disclosed. The implants may include a first cylindrical body with an outer surface, an axially extending hole, and a first end, a second cylindrical body with an outer surface and an axially extending hole, and an adjustment member with an outer surface, an axial hole, and at least one helical slot. The adjustment member axial hole may be adapted to receive the first cylindrical body and the adjustment member may be configured to be inserted into the axially extending hole of second cylindrical body. The implants may also include a travel mechanism for engaging the first cylindrical body, adjustment member, and second cylindrical body along the at least one helical slot to maintain a space between two bodies of tissue.

A method of producing an interbody spinal implant. The method includes the steps of obtaining a blank having a top surface, bottom surface, opposing lateral sides, and opposing anterior and posterior portions, and applying a subtractive process (e.g., masked acid etching) to the top surface, the bottom surface, or both surfaces of the blank to form a roughened surface topography. Subsequently, the blank is machined to form the interbody spinal implant, which includes a body having a top surface, a bottom surface, opposing lateral sides, opposing anterior and posterior portions, a substantially hollow center, and a single vertical aperture where the top surface, the bottom surface, or both surfaces of the interbody spinal implant have the roughened surface topography produced by the subtractive process. This simplified method produces more accurate and repeatable implants with fewer process steps and defects, reducing process time and costs.