An orthopaedic implant includes: a base including a molding material; a first porous ingrowth material region coupled to the base; a second porous ingrowth material region coupled to the base; and at least one barrier insert coupled to the base, the barrier insert including a barrier material that is configured to prevent introduction of the molding material of the base into some pores of the first porous ingrowth material region and some pores of the second porous ingrowth material region during molding of the base.

The present invention discloses a connected structure of a porous surface structure and a substrate, a method for preparing the same, and a prosthesis of the same. The connected structure consists of a pre-connected or integrally formed composite body of a porous surface structure and an intermediate; and a substrate, which is connected to said intermediate to achieve the connection of said composite body to the said substrate; the composite body comprising a first composite region corresponding to a first stiffness; a remaining composite region in the composite body other than the first composite region, which at least contains a second composite region corresponding to a second stiffness; and the first stiffness is less than the second stiffness. The present invention achieves a fastened connection between the composite and the substrate and largely maintains the mechanical properties of the substrate; and it provides a prosthesis with excellent bone ingrowth properties and that the strength of the substrate is not substantially affected.

There are provided herein methods and products resulting therefrom. The methods include attaching a pre-fabricated porous ingrowth structure to a substrate by applying heat, or creating and bonding an in-situ-formed porous ingrowth structure from beads on a substrate by applying heat. In some embodiments, an oxidized metal surface of the substrate is diffusion hardened during the heating process. In some embodiments, a vacuum is applied during the heating process. In some embodiments, pressure is applied during the heating process. Also provided herein are assemblies for compressing the pre-fabricated porous ingrowth structure or the beads onto the substrate during the heating process.

A tool for use with an orthopaedic implant includes: a tubular assembly including a tubular passage having a first end and a second end, the first end including a means for attachment to an implant body; a plug; and a plunger coupled to the plug. The tubular passage is configured to receive, via the second end, a material agent and the plunger coupled to the plug. The plunger is configured to slide through the tubular passage for expelling the material agent from the tubular passage into a load bearing member via the at least one first opening. The plunger is configured to rotate within the tubular passage for coupling the plug with the first opening to seal the first opening against expulsion of the material agent from the load bearing member via the first opening.

There are provided herein methods and products resulting therefrom. The methods include attaching a pre-fabricated porous ingrowth structure to a substrate by applying heat, or creating and bonding an in-situ-formed porous ingrowth structure from beads on a substrate by applying heat. In some embodiments, an oxidized metal surface of the substrate is diffusion hardened during the heating process. In some embodiments, a vacuum is applied during the heating process. In some embodiments, pressure is applied during the heating process. Also provided herein are assemblies for compressing the pre-fabricated porous ingrowth structure or the beads onto the substrate during the heating process.

A method of forming a composite titanium body for use in forming spinal implant interbodies includes selecting a metal alloy body, carving out a top portion and a bottom portion from the metal alloy body, and bonding a porous material to the carved-out top and bottom portions. Multiple pieces may be cut from the composite titanium body, each having a front face formed of the metal alloy, top and bottom portions formed of the porous material, and with a medial portion of the metal alloy extending from the front face to the back. Methods and devices for spinal interbodies having locking mechanisms to prevent bone screw back-out are also described.

This invention relates generally to spine surgery and, in particular, to a surgical implant for separating adjacent spinal vertebrae.

An exemplary process includes determining a desired pore size, selecting an initial pore size greater than the target pore size, manufacturing a porous structure with the initial pore size, forging the porous structure to form a forged part having the desired pore size, and forming an orthopedic device from the forged part.

A tool for use with an orthopaedic implant includes: a tubular assembly including a tubular passage having a first end and a second end, the first end including a means for attachment to an implant body; a plug; and a plunger coupled to the plug. The tubular passage is configured to receive, via the second end, a material agent and the plunger coupled to the plug. The plunger is configured to slide through the tubular passage for expelling the material agent from the tubular passage into a load bearing member via the at least one first opening. The plunger is configured to rotate within the tubular passage for coupling the plug with the first opening to seal the first opening against expulsion of the material agent from the load bearing member via the first opening.

Various embodiments of implant systems and related apparatus, and methods of operating the same are described herein. In various embodiments, an implant for interfacing with a bone structure includes a web structure, including a space truss, configured to interface with human bone tissue. The space truss includes two or more planar truss units having a plurality of struts joined at nodes. Implants are coated with, or have struts formed from, a piezoelectric material to enhance bone growth around and through the implant.