A medical implant which comprises a porous lattice is fabricated with additive manufacturing techniques such as direct metal laser sintering. A CAD model of the porous lattice is created by defining a trimming volume and merging some lattice elements with adjacent solid substrate.

A medical implant which comprises a porous lattice is fabricated with additive manufacturing techniques such as direct metal laser sintering. A CAD model of the porous lattice is created by defining a trimming volume and merging some lattice elements with adjacent solid substrate.

An implantable medical device is disclosed comprising a thermoplastic composite body having anterior, first lateral, second lateral, posterior, superior, and inferior surfaces, and at least one dense portion and at least one porous portion which are integrally formed. The at least one dense portion is formed of a first thermoplastic polymer matrix that is essentially non-porous, and which is continuous through a thickness dimension from the superior surface to the inferior surface. The at least one porous portion is formed of a porous thermoplastic polymer scaffold having a second thermoplastic polymer matrix which is continuous through the thickness dimension. A method for forming the thermoplastic composite body is disclosed comprising disposing a first powder mixture in a first portion of a mold, disposing a second powder mixture in a second portion of the mold, simultaneously molding the first powder mixture and the second powder mixture, and leaching porogen.

A knee prosthesis comprises a unicondylar knee prosthesis having a unicondylar insert platform and a tibial base attached to a bottom side of the unicondylar insert platform. The unicondylar insert platform has a uniform stiffness gradient (e.g., a density or porosity gradient), whereas the tibial base has a non-uniform stiffness gradient (e.g., a density or porosity gradient) when the tibial base is viewed from a cross-sectional coronal plan. For example, the tibial base may have an area of greatest stiffness or density centrally located relative to an inboard and outboard side of the tibial base. Alternatively, the area of greatest stiffness or density may be located toward the outboard side. Additionally, the tibial base may include density wells having increased density relative to the surrounding area of the tibial base.

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.

Disclosed is a method for forming an orthopaedic implant. The method comprises determining one or more parameters of a bone, of a subject, to which the implant is to be attached, and calculating specifications based on parameters. That calculation includes calculating a mechanical property relating to elasticity of the implant, a length of the implant, and positions of two or more fixation locations by which to fix the implant to the bone. The method further comprises forming the implant based on the specifications, wherein each fixation location comprises a longitudinal axis through the implant, and calculating specifications comprises calculating a trajectory for the longitudinal axis of the respective fixation location.

The variable or adjustable depth medical implants in this application are capable of depth adjustment prior to implantation. The variable depth implants permit a single implant to provide multiple footprint configurations, allowing a surgeon footprint adjustability in the operating room. The implants can comprise a metallic lattice designed for specific physical properties, such as an elastic modulus. In some examples, the main body of the implant is taller than the adjustable portion of the implant (also referred to as the second implant body) so that the physical properties of the main body of the implant are controlling at the implant site. In some embodiments, the variable implant is constructed in an additive process as a single unit.

An optimized press-fit between a resected bone and an articular implant may, for instance, reduce undesirable qualities, including excess micromotion, stress transmission, and/or strain. By taking into account heterogeneous bone properties, the parameters of a bone resection can be determined as to optimize the press-fit between a resected bone and an articular implant. An optimized press-fit is obtained by determining ideal engagement characteristics corresponding to the fit between the fixation features of an articular implant and a bone. Then, taking into account a bone's heterogeneous properties, the parameters of a bone resection that would substantially achieve the determined ideal engagement characteristics are determined.

The three-dimensional lattice structures disclosed herein have applications including use in medical implants, Some examples of the lattice structure are structural in that they can be used to provide structural support or mechanical spacing In some examples, the lattice can be configured as a scaffold to support bone or tissue growth Some examples can use a repeating modified rhombic dodecahedron or radial dodeca-rhombus unit cell. The lattice structures are also capable of providing a lattice structure with anisotropic properties to better suit the lattice for its intended purpose.

An implantable medical device is disclosed comprising a thermoplastic composite body having anterior, first lateral, second lateral, posterior, superior, and inferior surfaces, and at least one dense portion and at least one porous portion which are integrally formed. The at least one dense portion is formed of a first thermoplastic polymer matrix that is essentially non-porous, and which is continuous through a thickness dimension from the superior surface to the inferior surface. The at least one porous portion is formed of a porous thermoplastic polymer scaffold having a second thermoplastic polymer matrix which is continuous through the thickness dimension. A method for forming the thermoplastic composite body is disclosed comprising disposing a first powder mixture in a first portion of a mold, disposing a second powder mixture in a second portion of the mold, simultaneously molding the first powder mixture and the second powder mixture, and leaching porogen.