Abstract: The invention is directed to a method of making an orthopaedic implant. An orthopaedic implant body is formed which has a supporting surface. A porous metal pad is formed to fit the supporting surface of the body. The porous metal pad is clamped and/or adhesively bonded to the supporting surface. A laser beam is coupled between the porous metal pad and the implant body at a plurality of locations so as to form a coalescence of metal between the porous metal pad and the body.

Abstract: An orthopaedic implant body is formed which has a supporting surface. A porous metal pad is formed to fit the supporting surface of the body. The porous metal pad is clamped and/or adhesively bonded to the supporting surface. A laser beam is coupled between the porous metal pad and the implant body at a plurality of locations so as to form a coalescence of metal between the porous metal pad and the body.

Abstract: A method of forming an orthopaedic implant having a porous surface, the method including the steps of providing a porous surface including a porous layer attached to a substantially solid layer; positioning the porous layer on the orthopaedic implant; providing a high energy density welding device capable of producing a high energy density weld beam; and forming a weld bead substantially about the periphery of the porous layer by directing the high energy density weld beam about the periphery of the porous layer, wherein the weld bead bonds the porous layer to the implant. Two shaped porous pads may also be welded together about an implant body to avoid welding the body itself.

Abstract: A method of forming an orthopaedic implant having a porous surface, the method including the steps of providing a porous surface including a porous layer attached to a substantially solid layer; positioning the porous layer on the orthopaedic implant; providing a high energy density welding device capable of producing a high energy density weld beam; and forming a weld bead substantially about the periphery of the porous layer by directing the high energy density weld beam about the periphery of the porous layer, wherein the weld bead bonds the porous layer to the implant.

Abstract: The present invention comprises a flexible planar sheet having perimetric edges, the sheet being formed from a plurality of multi-fiber carbon filaments. The sheet is coated with a first solution of biodegradable polymer dissolved in a solvent, and the solvent is permitted to evaporate thereby leaving a first film of biodegradable polymer on the flexible sheet member. A second solution is applied to the sheet and contains a biodegradable polymer dissolved in a solvent, the concentration by weight of the polymer with respect to the solvent being greater in the second solution than in the first solution. When the solvent of the second solution evaporates it leaves a second film of biodegradable polymer on the planar sheet adjacent to the perimetric edges thereof. An alternative method of applying the polymer to the sheet is to lay polymer strips on the sheet and to apply heat to those polymer strips.