Abstract: A method for forming a molded article having an insert includes temporarily protecting features of the insert during a molding process using a malleable plugging material. In one step, the method includes disposing a plug including the plugging material within a receptacle of the insert, where each receptacle includes an engagement feature. The insert and the plugging material are placed into a mold, and a liquid molding material is applied to an exterior surface of the insert. The liquid molding material is solidified, forming the molded article including the insert embedded in the solidified molding material. The molded article is removed from the mold, and the plugging material is removed from the receptacle of the insert that is embedded in the molded article to expose the engagement feature.

Abstract: A set of distal femoral knee prostheses which are designed to be more narrow in medial/lateral dimensions with increasing anterior/posterior size than existing prostheses to more closely correspond to the physical anatomy of female patients. The prostheses are designed to have a substantially trapezoidal shape or profile when viewed distally which features a more pronounced narrowing of the medial/lateral dimensions beginning at the posterior end of the prostheses and progressing anteriorly to the anterior end of the prostheses. Additionally, the prostheses each include a reduced profile patellar sulcus and reduced profile anterior condyles to more closely conform to the anatomy of a resected femur, and also include sulcus tracking optimized to conform to female anatomy.

Abstract: A set of distal femoral knee prostheses which are designed to be more narrow in medial/lateral dimensions with increasing anterior/posterior size than existing prostheses to more closely correspond to the physical anatomy of female patients. The prostheses are designed to have a substantially trapezoidal shape or profile when viewed distally which features a more pronounced narrowing of the medial/lateral dimensions beginning at the posterior end of the prostheses and progressing anteriorly to the anterior end of the prostheses. Additionally, the prostheses each include a reduced profile patellar sulcus and reduced profile anterior condyles to more closely conform to the anatomy of a resected femur, and also include sulcus tracking optimized to conform to female anatomy.

Abstract: The improved joint prosthesis includes a metal-based substrate forming an articulatory surface for the joint prosthesis, wherein the metal-based substrate is coated with a ceramic or ceramic-based surface coating of a thin film doped silicon nitride (Si3N4) layer thereon, as disclosed in U.S. Pat. No. 6,881,229. The ceramic coating provides improvements in ultra-low wear over an extended service life, with dramatically reduced risk of brittle fracture when articulated or moved against articulation surfaces such as an acetabular cup in a hip prosthesis. In one preferred formation process, the ceramic coating is applied to the metal substrate by vapor deposition to mirror the surface finish of the substrate, and then polished to a smoother surface finish.

Abstract: An improved hlp prosthesis includes an acetabular cup bearing component constructed from a relatively hard and high strength ceramic material for articulation with a ball-shaped femoral head component which may be constructed from a compatible ceramic or metal material. In one form, the acetabular cup further includes a ceramic porous bone ingrowth surface adhered thereto for secure ingrowth attachment to natural patient bone.

Abstract: An improved hip prosthesis includes an acetabular cup bearing component constructed from a relatively hard and high strength ceramic material for articulation with a ball-shaped femoral head component which may be constructed from a compatible ceramic or metal material. In one form, the acetabular cup further includes a ceramic porous bone ingrowth surface adhered thereto for secure ingrowth attachment to natural patient bone.

Abstract: The present invention is directed to a rotating/non-rotating tibia base plate/insert system. In one illustrative embodiment, the device comprises a tibia base plate, an insert adapted to be positioned above the base plate, and at least one removable pin that, when installed, engages at least a portion of the insert and the base plate to thereby prevent relative rotation between the insert and the base plate.

Abstract: A set of distal femoral knee prostheses which are designed to be more narrow in medial/lateral dimensions with increasing anterior/posterior size than existing prostheses to more closely correspond to the physical anatomy of female patients. The prostheses are designed to have a substantially trapezoidal shape or profile when viewed distally which features a more pronounced narrowing of the medial/lateral dimensions beginning at the posterior end of the prostheses and progressing anteriorly to the anterior end of the prostheses. Additionally, the prostheses each include a reduced profile patellar sulcus and reduced profile anterior condyles to more closely conform to the anatomy of a resected femur, and also include sulcus tracking optimized to conform to female anatomy.

Abstract: An improved hip prosthesis includes an acetabular cup bearing component constructed from a relatively hard and high strength ceramic material for articulation with a ball-shaped femoral head component which may be constructed from a compatible ceramic or metal material. In one form, the acetabular cup further includes a ceramic porous bone ingrowth surface adhered thereto for secure ingrowth attachment to natural patient bone.

Abstract: A ceramic-metal composite articulation is provided with substantial elimination of wear debris, wherein a ceramic material is provided with superior mechanical properties tailored for articulating with ceramic articulations having high flexural strength (greater than about 700 MPa), high fracture toughness (greater than about 7 MPam1/2) and a high Weibull modulus (greater than about 20), in comparison with presently available bio-ceramics such as alumina or zirconia. The mechanical property enhancement enables ceramic materials with greater reliability and significantly reduced in-vivo fracture risk to be obtained. Preliminary in-vitro wear performance, to several million cycles using established test protocols, of head/cup components in a prosthetic hip joint made from these ceramics also demonstrates the ultra low wear characteristics.

Abstract: An improved knee prosthesis includes a ceramic tibial component for articulation with natural or prosthetic (re-surfaced) femoral surfaces. The ceramic tibial component is provided in the form of a ceramic monoblock adapted for fixation relative to the patient's tibial bone, or alternately in the form of a ceramic bearing insert component carried by a tibial baseplate member which is adapted in turn for fixation relative to tibial bone. In either form, the ceramic tibial component includes at least one upwardly concave articulation surface for movable bearing engagement by a generally convex or condylar shaped femoral articulation surface. The ceramic tibial component provides improved wear characteristics with extended service life.

Abstract: An improved hip prosthesis includes an acetabular cup bearing component constructed from a relatively hard and high strength ceramic material for articulation with a ball-shaped femoral head component which may be constructed from a compatible ceramic or metal material. In one form, the acetabular cup further includes a ceramic porous bone ingrowth surface adhered thereto for secure ingrowth attachment to natural patient bone.

Abstract: A set of distal femoral knee prostheses which are designed to be more narrow in medial/lateral dimensions with increasing anterior/posterior size than existing prostheses to more closely correspond to the physical anatomy of female patients. The prostheses are designed to have a substantially trapezoidal shape or profile when viewed distally which features a more pronounced narrowing of the medial/lateral dimensions beginning at the posterior end of the prostheses and progressing anteriorly to the anterior end of the prostheses. Additionally, the prostheses each include a reduced profile patellar sulcus and reduced profile anterior condyles to more closely conform to the anatomy of a resected femur, and also include sulcus tracking optimized to conform to female anatomy.

Abstract: An improved knee prosthesis includes a ceramic tibial component for articulation with natural or prosthetic (re-surfaced) femoral surfaces. The ceramic tibial component is provided in the form of a ceramic monoblock adapted for fixation relative to the patient's tibial bone, or alternately in the form of a ceramic bearing insert component carried by a tibial baseplate member which is adapted in turn for fixation relative to tibial bone. In either form, the ceramic tibial component includes at least one upwardly concave articulation surface for movable bearing engagement by a generally convex or condylar shaped femoral articulation surface. The ceramic tibial component provides improved wear characteristics with extended service life.

Abstract: An improved hip prosthesis includes an acetabular cup bearing component constructed from a relatively hard and high strength ceramic material for articulation with a ball-shaped femoral head component which may be constructed from a compatible ceramic or metal material. In one form, the acetabular cup further includes a ceramic porous bone ingrowth surface adhered thereto for secure ingrowth attachment to natural patient bone.

Abstract: A ceramic-metal composite articulation is provided with substantial elimination of wear debris, wherein a ceramic material is provided with superior mechanical properties tailored for articulating with ceramic articulations having high flexural strength (greater than about 700 MPa), high fracture toughness (greater than about 7 MPam1/2) and a high Weibull modulus (greater than about 20), in comparison with presently available bio-ceramics such as alumina or zirconia. The mechanical property enhancement enables ceramic materials with greater reliability and significantly reduced in-vivo fracture risk to be obtained. Preliminary in-vitro wear performance, to several million cycles using established test protocols, of head/cup components in a prosthetic hip joint made from these ceramics also demonstrates the ultra low wear characteristics.

Abstract: A ceramic-metal composite articulation is provided with substantial elimination of wear debris, wherein a ceramic material is provided with superior mechanical properties tailored for articulating with ceramic articulations having high flexural strength (greater than about 700 MPa), high fracture toughness (greater than about 7 MPam1/2) and a high Weibull modulus (greater than about 20), in comparison with presently available bio-ceramics such as alumina or zirconia. The mechanical property enhancement enables ceramic materials with greater reliability and significantly reduced in-vivo fracture risk to be obtained. Preliminary in-vitro wear performance, to several million cycles using established test protocols, of head/cup components in a prosthetic hip joint made from these ceramics also demonstrates the ultra low wear characteristics.

Abstract: A ceramic-metal composite articulation is provided with substantial elimination of wear debris, wherein a ceramic material is provided with superior mechanical properties tailored for articulating with ceramic articulations having high flexural strength (greater than about 700 MPa), high fracture toughness (greater than about 7 MPa1/2) and a high Weibull modulus (greater than about 20), in comparison with presently available bio-ceramics such as alumina or zirconia. The mechanical property enhancement enables ceramic materials with greater reliability and significantly reduced in-vivo fracture risk to be obtained. Preliminary in-vitro wear performance, to several million cycles using established test protocols, of head/cup components in a prosthetic hip joint made from these ceramics also demonstrates the ultra low wear characteristics.

Abstract: The present invention is directed to a rotating/non-rotating tibia base plate/insert system. In one illustrative embodiment, the device comprises a tibia base plate, an insert adapted to be positioned above the base plate, and at least one removable pin that, when installed, engages at least a portion of the insert and the base plate to thereby prevent relative rotation between the insert and the base plate.

Abstract: A ceramic-metal composite articulation is provided with substantial elimination of wear debris, wherein a ceramic material is provided with superior mechanical properties tailored for articulating with ceramic articulations having high flexural strength (greater than about 700 MPa), high fracture toughness (greater than about 7 MPam1/2) and a high Weibull modulus (greater than about 20), in comparison with presently available bio-ceramics such as alumina or zirconia. The mechanical property enhancement enables ceramic materials with greater reliability and significantly reduced in-vivo fracture risk to be obtained. Preliminary in-vitro wear performance, to several million cycles using established test protocols, of head/cup components in a prosthetic hip joint made from these ceramics also demonstrates the ultra low wear characteristics.