Abstract: A method of fabricating a material having a high concentration of a carbide constituent. The method may comprise adding a carbide source to a biocompatible material in which a weight of the carbide source is at least approximately 10% of the total weight, heating the carbide source and the biocompatible material to a predetermined temperature to melt the biocompatible material and allow the carbide source to go into solution to form a molten homogeneous solution, and impinging the molten homogeneous solution with a high pressure fluid to form spray atomized powder having carbide particles. The size of a particle of carbide in the atomized powder may be approximately 900 nanometers or less. The biocompatible material may be cobalt chrome, the carbide source may be graphite, and the fluid may be a gas or a liquid.

Abstract: A prosthetic head for a femoral component has a metal shell with a tapered cavity. The shell has a part-spherical outer surface defining an inner portion terminating in an open end. A polymeric material completely fills the inner portion of the hollow shell extending from an inner surface of the shell to the open end. The polymeric material includes a conically tapered socket centered about the polar axis intermediate ends of the open end wherein the shell is a hollow titanium shell having an inner surface with a porous structure for receiving a portion of the polymeric material. The hollow titanium shell inner surface has at least one rib extending inwardly toward the conically tapered socket.

Abstract: A method of fabricating a material having a high concentration of a carbide constituent. The method may comprise adding a carbide source to a biocompatible material in which a weight of the carbide source is at least approximately 10% of the total weight, heating the carbide source and the biocompatible material to a predetermined temperature to melt the biocompatible material and allow the carbide source to go into solution to form a molten homogeneous solution, and impinging the molten homogeneous solution with a high pressure fluid to form spray atomized powder having carbide particles. The size of a particle of carbide in the atomized powder may be approximately 900 nanometers or less. The biocompatible material may be cobalt chrome, the carbide source may be graphite, and the fluid may be a gas or a liquid.

Abstract: A method of fabricating a material having a high concentration of a carbide constituent. The method may comprise adding a carbide source to a biocompatible material in which a weight of the carbide source is at least approximately 10% of the total weight, heating the carbide source and the biocompatible material to a predetermined temperature to melt the biocompatible material and allow the carbide source to go into solution to form a molten homogeneous solution, and impinging the molten homogeneous solution with a high pressure fluid to form spray atomized powder having carbide particles. The size of a particle of carbide in the atomized powder may be approximately 900 nanometers or less. The biocompatible material may be cobalt chrome, the carbide source may be graphite, and the fluid may be a gas or a liquid.

Abstract: A prosthetic head for a femoral component has a metal shell with a tapered cavity. The shell has a part-spherical outer surface defining an inner portion terminating in an open end. A polymeric material completely fills the inner portion of the hollow shell extending from an inner surface of the shell to the open end. The polymeric material includes a conically tapered socket centered about the polar axis intermediate ends of the open end wherein the shell is a hollow titanium shell having an inner surface with a porous structure for receiving a portion of the polymeric material. The hollow titanium shell inner surface has at least one rib extending inwardly toward the conically tapered socket.

Abstract: A method of manufacturing an orthopaedic implant device having a porous outer surface is described. In one embodiment, the implant device includes a porous layer, an intermediate layer, and a solid substrate. The porous layer is preferably bonded to the intermediate layer by cold isostatic pressing. The intermediate layer is preferably bonded by vacuum welding to the solid substrate such that the porous layer forms at least a portion of the outer surface of the orthopaedic implant device. Preferably, a diffusion bond is created between the bonded intermediate layer and the solid substrate by hot isostatic pressing. In another embodiment, a porous layer is created on an outer surface of a solid layer by selective melting. Preferably, the solid layer is bonded to the solid substrate such that the porous layer forms at least a portion of the outer surface of the orthopaedic implant device.

Abstract: A method of manufacturing an orthopaedic implant device having a porous outer surface is described. In one embodiment, the implant device includes a porous layer, an intermediate layer, and a solid substrate. The porous layer is preferably bonded to the intermediate layer by cold isostatic pressing. The intermediate layer is preferably bonded by vacuum welding to the solid substrate such that the porous layer forms at least a portion of the outer surface of the orthopaedic implant device. Preferably, a diffusion bond is created between the bonded intermediate layer and the solid substrate by hot isostatic pressing. In another embodiment, a porous layer is created on an outer surface of a solid layer by selective melting. Preferably, the solid layer is bonded to the solid substrate such that the porous layer forms at least a portion of the outer surface of the orthopaedic implant device.

Abstract: A method of fabricating a material having a high concentration of a carbide constituent. The method may comprise adding a carbide source to a biocompatible material in which a weight of the carbide source is at least approximately 10% of the total weight, heating the carbide source and the biocompatible material to a predetermined temperature to melt the biocompatible material and allow the carbide source to go into solution to form a molten homogeneous solution, and impinging the molten homogeneous solution with a high pressure fluid to form spray atomized powder having carbide particles. The size of a particle of carbide in the atomized powder may be approximately 900 nanometers or less. The biocompatible material may be cobalt chrome, the carbide source may be graphite, and the fluid may be a gas or a liquid.

Abstract: A medical implant component and a method for fabricating the same are provided. The medical implant component may comprise a substrate having a bearing portion, in which at least the bearing portion has a coating of at least 25 micrometers of a predetermined material. The predetermined material of the coating may include chromium ceramic having a chromium component which releases less than approximately 7 parts of hexavalent chromium per billion parts of water solution when the medical implant component is immersed in approximately 500 milliliters of water for approximately one week at a temperature in a range of room temperature to just below a boiling point of the water at atmospheric pressure. The residual stress of the coating may be less than approximately 100,000 pounds per square inch. The chromium ceramic may be a chromium oxide, a chromium carbide, a chromium nitride, or a chromium boride, or any combination thereof.

Abstract: An implant and a method for forming an implant. The implant includes a fixation surface having at least a portion made up of an oxidized material.

Abstract: A refined chromium oxide powder having a reduced level of hexavalent chromium. The refined powder may be produced by acid and reduction washing or by heat treatment to reduce the hexavalent chromium to a biocompatible level. The powder is then packaged to limit oxidation and absorption of moisture.

Abstract: EMI feedthrough filter terminal assembly includes a feedthrough filter capacitor having first and second sets of electrode plates, and a first passageway having a first termination surface conductively coupling the first set of electrode plates. At least one lead wire extends through the first passageway and is conductively attached to a first oxide resistant conductive pad. The first pad is conductively coupled to the first termination surface independently of the lead wire. The terminal assembly may also include a conductive ferrule through which the lead wire passes in non-conductive relation, and an insulator fixed to the ferrule for conductively isolating the lead wire from the ferrule. The ferrule and insulator form a pre-fabricated hermetic terminal pin sub-assembly. The capacitor may include a second passageway having a second termination surface conductively coupling the second set of electrode plates, and a conductive ground lead extending therethrough.

Abstract: An EMI feedthrough filter terminal assembly includes a capacitor having first and second sets of electrode plates, a first passageway having a first termination surface coupling the first set of electrode plates, a second passageway having a second termination surface coupling the second set of electrode plates, and a third termination surface exteriorly coupling the second set of electrode plates. A ferrule is adjacent to the capacitor and includes an oxide resistant biostable conductive pad, i.e., a noble metal pad, on a surface thereof coupled to the third termination surface. A conductive terminal pin extends through the first passageway in conductive relation with the first set of electrode plates. A conductive ground lead extends through the second passageway in conductive relation with the second set of electrode plates. An insulator is fixed to the ferrule for supporting the terminal pin in conductive isolation from the ferrule.

Abstract: An EMI feedthrough filter terminal assembly includes a feedthrough filter capacitor having first and second sets of electrode plates, a passageway having a first termination surface conductively coupling the first set of electrode plates, and a second termination surface exteriorly coupling the second set of electrode plates. A conductive ferrule disposed adjacent to the capacitor includes a conductive pad of an oxide resistant biostable material on a surface thereof conductively coupled to the second termination surface. A conductive terminal pin extends through the passageway in conductive relation with the first set of electrode plates, and through the ferrule in non-conductive relation. An insulator is fixed to the ferrule for conductively isolating the terminal pin from the ferrule. A hermetic seal is disposed between the insulator and the ferrule. A second conductive pad may be conductively attached to the terminal pin and to the first termination surface independently of the lead wire.

Abstract: EMI feedthrough filter terminal assembly includes a feedthrough filter capacitor having first and second sets of electrode plates, and a first passageway having a first termination surface conductively coupling the first set of electrode plates. At least one lead wire extends through the first passageway and is conductively attached to a first oxide resistant conductive pad. The first pad is conductively coupled to the first termination surface independently of the lead wire. The terminal assembly may also include a conductive ferrule through which the lead wire passes in non-conductive relation, and an insulator fixed to the ferrule for conductively isolating the lead wire from the ferrule. The ferrule and insulator form a pre-fabricated hermetic terminal pin sub-assembly. The capacitor may include a second passageway having a second termination surface conductively coupling the second set of electrode plates, and a conductive ground lead extending therethrough.

Abstract: An EMI feedthrough filter terminal assembly includes a capacitor having first and second sets of electrode plates, a first passageway having a first termination surface coupling the first set of electrode plates, a second passageway having a second termination surface coupling the second set of electrode plates, and a third termination surface exteriorly coupling the second set of electrode plates. A ferrule is adjacent to the capacitor and includes an oxide resistant biostable conductive pad, i.e., a noble metal pad, on a surface thereof coupled to the third termination surface. A conductive terminal pin extends through the first passageway in conductive relation with the first set of electrode plates. A conductive ground lead extends through the second passageway in conductive relation with the second set of electrode plates. An insulator is fixed to the ferrule for supporting the terminal pin in conductive isolation from the ferrule.

Abstract: An EMI feedthrough filter terminal assembly includes a feedthrough filter capacitor having first and second sets of electrode plates, a passageway having a first termination surface conductively coupling the first set of electrode plates, and a second termination surface exteriorly coupling the second set of electrode plates. A conductive ferrule disposed adjacent to the capacitor includes a conductive pad of an oxide resistant biostable material on a surface thereof conductively coupled to the second termination surface. A conductive terminal pin extends through the passageway in conductive relation with the first set of electrode plates, and through the ferrule in non-conductive relation. An insulator is fixed to the ferrule for conductively isolating the terminal pin from the ferrule. A hermetic seal is disposed between the insulator and the ferrule. A second conductive pad may be conductively attached to the terminal pin and to the first termination surface independently of the lead wire.