Abstract: A novel process for creating porous structures via additive manufacturing processes such as material deposition or powder bed fusion additive manufacturing is provided. The process reduces the computational requirement for generation of the porous structure geometry and for processing the porous structure geometry to generate CNC code. The process provides reduced file size for CNC code and avoids large files which may exceed capacity of manufacturing machines. The process also significantly reduces the time required to manufacture the porous structure on an additive manufacturing machine.

Abstract: A porous implant for repairing lost bone stock such as around a prosthetic joint is provided. The porous implant has a composite structure with a solid structure and a porous structure which may be formed monolithically by direct metal laser sintering. The solid structure includes a support structure which extends into the porous structure.

Abstract: A novel process for creating porous structures via powder bed fusion additive manufacturing is provided. The process reduces the computational requirement for generation of the porous structure geometry and for processing the porous structure geometry to generate CNC code. The process provides reduced file size for CNC code and avoids large files which may exceed capacity of manufacturing machines. The process also significantly reduces the time required to sinter the porous structure on a powder bed fusion manufacturing machine.

Abstract: A method and tool for inserting a prosthetic stem component in an aligned position into a prepared bone cavity. The bone is prepared by removing bone material from the bone canal and preferably also machining an entry opening of a predetermined shape and desired orientation in the bone, or marking the plane of the joint on the bone end. The tool includes an upper component that engages the top of the prosthesis stem to fix its rotational alignment, and an arm that extends to the opening in the bone and is aligned at its distal end. The upper component rides along the arm, and orients the stem with respect to the bone as the stem is inserted. The tool may include a lower element that engages the machined or marked bone and holds the arm to orient the head of the prosthesis. Optionally, the lower element may guide the distal stem. Alternatively, the guide may include an arm that simply points to, contacts or fastens at the bone end, orienting the prosthesis insertion without sighting errors.

Abstract: A proximally hollow prosthesis is provided having a cap element and a stem; the prosthesis, in one embodiment, has a cap element suitable to be adapted to a ball and hip socket and has a stem suitable to be implanted in a reamed femoral medullary canal. The stem of the prosthesis has a proximal region and a distal region and is mateable with the cap element of the prosthesis. The proximal region of the stem is open to define a cavity which extends longitudinally a predetermined distance through the proximal region of the stem but not into an isthmus region of the stem, which is located distal to the proximal region of the stem. The distal region of the stem is located distal to the isthmus region of the stem and is made of solid metal or alloys thereof. In another embodiment of the invention, the distal region of the stem is furcated, being at least bifurcated so as to define a plurality of tangs.

Abstract: A prosthetic stem inserter device includes an elongate rod member having a handle portion and an elongate rod member having a distal portion which has a plurality of surface features formed thereon which define a series of predetermined stem insertion depths. The device further includes a depth guide member having a proximal portion removably and replaceably engageable with the surface features on the elongate rod member. A distal, bone engaging portion of the depth guide member protrudes beyond a distal end of the elongate rod member. The depth guide member includes a mounting plate having a substantially hemispherical opening slot therein and a pair of distally extending prong elements. Each prong element has a first, longitudinally extending portion and a second portion that is angled with respect to the first portion. The second portion is adapted for contacting a plane of calcar bone in a prepared femoral cavity when a femoral stem is inserted into the cavity.

Abstract: A femoral head trial adaptor for converting a shell trial to a head trial includes a barrel member having an outer surface and an inner surface defining a cavity for receiving a femoral neck trial. A circumferential flange portion is located on the outer surface of the barrel member. A resilient connecting member disposed on the circumferential flange has a nominal first diameter compressible to a smaller second diameter in response to a force and returnable to the first diameter in the absence of the force for securing the trial adaptor to a shell trial. The flange may be located at a predetermined position along the outer surface of the barrel member so as to simulate a neck trial of a given length.

Abstract: A modular acetabular reinforcement system includes a substantially cup-shaped reinforcement body having a peripheral flange portion. One or more fixation wings, of various sizes and shapes, are selectively and separately attachable to the flange portion of the reinforcement body. The system is mountable within the acetabulum of a patient to reinforce the acetabulum and to serve as a platform for other prosthesis components such as an acetabular shell.