Abstract: Provided herein are surgical implants and methods of manufacturing the implants. The implants are generally osteoconductive composite implants utilizing minimally-crosslinked acrylic carriers combined with osteoconductive ceramics. The methods generally involve dissolving a monomer and an initiator in a solvent to form a reaction mixture, controlling the temperature and viscosity of the reaction mixture to allow solution polymerization, polymerizing the monomer in the reaction mixture to form an acrylic carrier, recovering the acrylic carrier, extruding the acrylic carrier with an osteoconductive ceramic to form an osteoconductive biomaterial, and processing the osteoconductive biomaterial to form the osteoconductive composite implant.

Abstract: Provided herein are surgical implants and methods of manufacturing the implants. The surgical implant includes an outer body made of a polymer, at least one internal strut coupled to the outer body, where the internal strut has a smaller diameter than the outer body, and ceramic granules deposited on the surface of the internal strut. Methods of manufacturing a surgical implant generally include injecting a molten mixture containing a polymer and ceramic particles into a mold. The mold defines a negative space for forming the implant. As the molten mixture flows through the negative space, the mold constricts the flow at the internal strut, causing the ceramic granules to deposit on the surface of the internal strut. The mixture is then cooled to form the implant, with the ceramic granules at least partially exposed on its surface.