Abstract: A composite interbody device includes (a) a plastic core having a superior surface and an inferior surface, (b) a superior endplate and (c) an inferior endplate. Each of the superior and inferior endplates includes (i) a bone interface side for interfacing with bone and having a plurality of pores permitting bone growth therein, and (ii) a core interface side, opposite the bone interface side, having a plurality of voids that accommodate material of the plastic core to couple the endplate to a respective one of the superior and inferior surfaces, wherein the voids are isolated from the pores to prevent the material of the plastic core from entering the pores.

Abstract: A method of manufacturing a composite interbody device includes assembling superior and inferior endplates, this including forming or layering micro-porous titanium on opposing sides of a solid titanium sheet. A first of the opposing sides provides a micro-porous bone interface layer and a second of the opposing sides provides a micro-porous core interface side. The solid titanium sheet therebetween forms a central barrier layer. The inferior and superior endplates are placed in a mold, on each side of a core cavity, with the core interface sides facing the core cavity and the bone interface sides facing away from the cavity. Molten plastic is injection-molded into the core cavity to form a plastic core between the endplates, the molten plastic extruding into pores of the microporous core interface sides. The plastic is set to bond the core with the endplates.

Abstract: A method of manufacturing a composite interbody device includes assembling superior and inferior endplates, this including forming or layering micro-porous titanium on opposing sides of a solid titanium sheet. A first of the opposing sides provides a micro-porous bone interface layer and a second of the opposing sides provides a micro-porous core interface side. The solid titanium sheet therebetween forms a central barrier layer. The inferior and superior endplates are placed in a mold, on each side of a core cavity, with the core interface sides facing the core cavity and the bone interface sides facing away from the cavity. Molten plastic is injection-molded into the core cavity to form a plastic core between the endplates, the molten plastic extruding into pores of the microporous core interface sides. The plastic is set to bond the core with the endplates.

Abstract: A composite interbody device includes superior and inferior endplates with a plastic core molded therebetween. The core includes one or more features for permitting bone growth through the core. Each endplate includes a bone interface side coated with hydroxyapatite, for promoting bone on-growth. Pores in the bone interface sides permit bone in-growth. Core interface sides of the endplates include relatively larger pores for accepting molten material from the core, for example during injection molding, to enhance bonding of the endplates with the core. Each endplate has a central barrier layer for preventing the molten core material from extruding through the core interface pores into the bone interface pores, reserving the bone interface pores for bone in-growth. A method of manufacturing the composite interbody device is also disclosed.

Abstract: A composite interbody device includes superior and inferior endplates with a plastic core molded therebetween. The core includes one or more features for permitting bone growth through the core. Each endplate includes a bone interface side coated with hydroxyapatite, for promoting bone on-growth. Pores in the bone interface sides permit bone in-growth. Core interface sides of the endplates include relatively larger pores for accepting molten material from the core, for example during injection molding, to enhance bonding of the endplates with the core. Each endplate has a central barrier layer for preventing the molten core material from extruding through the core interface pores into the bone interface pores, reserving the bone interface pores for bone in-growth. A method of manufacturing the composite interbody device is also disclosed.

Abstract: A composite interbody device includes superior and inferior endplates with a plastic core molded therebetween. The core includes one or more features for permitting bone growth through the core. Each endplate includes a bone interface side coated with hydroxyapatite, for promoting bone on-growth. Pores in the bone interface sides permit bone in-growth. Core interface sides of the endplates include relatively larger pores for accepting molten material from the core, for example during injection molding, to enhance bonding of the endplates with the core. Each endplate has a central barrier layer for preventing the molten core material from extruding through the core interface pores into the bone interface pores, reserving the bone interface pores for bone in-growth. A method of manufacturing the composite interbody device is also disclosed.