Abstract: Novel composite orthopedic devices with modulus variations are disclosed. The device contains an extraosseous portion attached to a first intraosseous portion which is secured to a second intraosseous portion; the intraosseous portions may interface with the intramedullary canal of the human femur. The modulus varies along the length of the device, decreasing from the extraosseous portion to the second intraosseous portion. The variations in modulus are achieved by forming the device from a composite comprising filaments nonlinearly disposed about the longitudinal axes of the device and within a polymer matrix. The method of making the present orthopedic device is also disclosed.

Abstract: A panel comprising a core member in the form of a honeycomb structure of aramid paper and thermoplastic resin sheet material reinforced with a fiber selected from the group consisting of aramid, carbon and glass bonded to both sides of said core member to form facings therefor.

Abstract: A novel procedure for molding composite structures is disclosed wherein the finished part exhibits a net shape geometry requiring minimal further machining and displaying enhanced consolidation and surface characteristics. A composite preform having a hollow core portion containing a polymer insert is introduced into a mold cavity. One end of the preform core is sealed and the preform together with the polymer insert is heated to melt the composite matrix and core polymer. Pressure is applied to the core at the other end of the part, causing radial expansion of the part against the molded cavity and consolidation of the composite into a finished part. A product finished part is also disclosed and is useful as a component of an orthopedic implant.

Abstract: A control system for controlling the edge thickness of an extrudate includes an arrangement responsive to a signal representative of the monitored thickness of the extrudate emanating from a die slot controlled by a transversely inward heating element for generating a control set point for that heating element and for a heating element controlling the die slot adjacent a lateral edge thereof.

Abstract: A thickness control system for controlling the thickness of an extrudate includes a nested temperature control loop for controlling the temperature of a heat responsive element based upon a predetermined temperature set point. The temperature set point for the temperature control loop is computed based upon the measured thickness of the extrudate.