Abstract: A method for forming a three-dimensional, biocompatible, porous scaffold structure using a solid freeform fabrication technique (referred to herein as robocasting) that can be used as a medical implant into a living organism, such as a human or other mammal. Imaging technology and analysis is first used to determine the three-dimensional design required for the medical implant, such as a bone implant or graft, fashioned as a three-dimensional, biocompatible scaffold structure. The robocasting technique is used to either directly produce the three-dimensional, porous scaffold structure or to produce an over-sized three-dimensional, porous scaffold lattice which can be machined to produce the designed three-dimensional, porous scaffold structure for implantation.

Abstract: A coated prosthetic implant and a method of forming a continuous coating of highly crystalline polymer over a prosthetic implant by means of passing particles of polymer through a high temperature plasma and subsequently depositing the molten particles over the implant surface. This invention is especially useful for coating polymer composite implants, such as a femoral insert for a hip joint prosthesis, with a coating of poly (aryl-ether-ketone).

Abstract: A method and apparatus for the fixation of bone fractures, limb lengthening, and the correction of deformities uses an improved composite plastic carbon fiber ring that is formed in a mold, or machined with a stepped end portion that allows half rings to be assembled in a common plane. The method can use a mold wherein multiple rings can be formed by stacking the rings with a Teflon layer therebetween and wherein circumferential braid reinforcement of carbon fiber adds strength at the circumferential inner and outer curved surfaces of the rings and half rings.

Abstract: The invention provides biocompatible, corrosion-resistant prostheses and methods for producing these. A coating comprising a bismaleimide-triazine resin, a biocompatible plasticizer and optionally a thickener is applied to a prosthesis substrate and the resin is cured to provide a tightly adherent, biocompatible, corrosion-resistant coating. Radio-opaque materials, such as barium sulfate, may be included in the coating as well as bone ingrowth materials such as hydroxyapatite.