An implant is produced by fabricating first and second layers. The first layer of repeated and truncated building units is fused together to define pores. The second layer of repeated and truncated building units are fused together to define pores and fused onto the first layer of truncated building units. The first and the second layers form at least part of a porous portion of the implant. The formed porous portion is attached onto a base portion of an implant. The truncated building units of each of the first and the second layers are in the form of spatially overlapping three-dimensional shapes.

The present invention includes a method for generating a three-dimensional model of a bone and generating a cut plan for excavating a portion of the bone according to the cut plan to allow the insertion of a custom implant. In a particular arrangement, the method also includes excavating the bone with an autonomous extremity excavator utilizing the cut plan generated by a processor. In a further arrangement, the method includes generating a digital model of a custom implant and generating, using the digital model, a physical model sharing the same dimensions as the digital module using manufacturing device.

A method of manufacturing an implant is disclosed. The method includes preparing a wax template assembly based upon anatomical characteristics of an implantation site. Post formation of the template assembly, a lamination layer is provided over the template assembly resulting in a laminated template assembly. The lamination layer is composed of at least one polymer dissolved in one or more solvents. One or more coating layers of a pre-defined coating material are provided over the laminated template assembly to prepare a mold. The mold may then be sand-rained to form a sand coated mold. The sand coated mold may be de-waxed and baked for melting out the template assembly to form a de-waxed mold. A casting material is then poured over the de-waxed mold to form a casted mold which is cooled and solidified to form a casted implant which is further heat treated and finished to form the implant.

An orthopaedic prosthesis includes a femoral component comprising polymeric materials. The polymeric materials may include a polyaromatic ether or a polyacetal. The orthopaedic prosthesis may include a component having an articular layer and a support layer adjacent the articular layer. The support layer may include a reinforcement fiber. The orthopaedic prosthesis may be a knee prosthesis.

Described is a mould (1) for making a temporary prosthetic component for a knee in an operating room comprising: a first half-mould (10); a second half-mould (20) which can be coupled to the first half-mould (10) for forming a moulding chamber (C) for a temporary prosthetic component made of medical cement; and elements (30) for fixing the first half-mould (10) to the second half-mould (20). Each fixing element (30) has a rod (31) configured for connecting the first half-mould (10) to the second half-mould (20) and defining a weakness neck (32) configured to allow a facilitated breakage of the rod (31).

An orthopaedic implant includes a femoral component having a metallic zirconium and niobium coating disposed therein. A method of making the femoral component using direct energy deposition or co-molding is also disclosed.

A method for forming a thermoplastic body having regions with varied material composition and/or porosity. Powder blends comprising a thermoplastic polymer, a sacrificial porogen and an inorganic reinforcement or filler are molded to form complementary parts with closely toleranced mating surfaces. The parts are formed discretely, assembled and compression molded to provide a unitary article that is free from discernible boundaries between the assembled parts. Each part in the assembly has differences in composition and/or porosity, and the assembly has accurate physical features throughout the sections of the formed article, without distortion and nonuniformities caused by variable compaction and densification rates in methods that involve compression molding powder blends in a single step.

A system and method for providing a spinal implant having a main body, a proximal anchor, a distal anchor, and an internal plunger. The proximal anchor comprises a nut having an internal bore. The distal anchor comprises a plurality of wings having a first closed configuration and a second open configuration. The internal plunger is housed within a central bore of the main body. The distal end of the internal plunger is operatively connected to the first wing and the second wing to selectively move the wings between the first closed configuration and the second open configuration, and vice versa.

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.

An implant shredder includes a base and a cutting member. The base includes a first chamber and a second chamber intercommunicating with the first chamber. The first chamber includes an inlet. The second chamber includes an outlet. The cutting member is received in the second chamber. The cutting member is driven by a driving member to rotate. The cutting member includes a plurality of cutting edges located on a circumference of a same radius. The plurality of cutting edges is rotatably disposed adjacent to a location intercommunicating with the first chamber. An implant forming method includes creating data of an outline of an implant; producing a shaping mold based on the data; and cutting a to-be-processed object with the implant shredder, mixing the cut to-be-proceed object with a biological tissue glue to obtain a raw material, and filling the raw material into the shaping mold to form the implant.