Abstract: An implant articular surface wear reduction system improves orthopedic prosthetic joint longevity by reducing frictional abrasive wear. The system includes a polymeric implant component and a rigid implant component. A hard wear layer is attached to the polymeric implant. The hard wear layer represents one opposing articular surface of a joint. The rigid implant component has a working surface and may represent another opposing articular surface in the joint. In one embodiment, the rigid implant component and the hard wear layer are ceramic. In another embodiment, a non-metallic wear layer is attached to the working surface. The non-metallic wear layer represents another opposing articular surface of the joint. In one embodiment, the polymeric implant component is a tibial implant and the rigid implant component is a femoral implant and the non-metallic wear layer is a polymer, such as polyethylene, self-reinforced polyphenylene, or PEEK.

Abstract: A method for attaching a porous metal layer to a dense metal substrate, wherein the method is particularly useful in forming orthopedic implants such as femoral knee components or acetabular cups. The method, in one embodiment thereof, comprises providing a structured porous layer; providing a dense metal substrate; providing a binding mixture; applying the binding mixture to the exterior of the substrate; placing the porous layer against the substrate such that the binding mixture is disposed there between forming an assembly; and heat treating the assembly to metallurgically bond the porous layer to the substrate.