Abstract: An apparatus and method are provided for manufacturing an orthopedic prosthesis by resistance welding a porous metal layer of the orthopedic prosthesis onto an underlying metal substrate of the orthopedic prosthesis. The resistance welding process involves directing an electrical current through the porous layer and the substrate, which dissipates as heat to cause softening and/or melting of the materials, especially along the interface between the porous layer and the substrate. The softened and/or melted materials undergo metallurgical bonding at points of contact between the porous layer and the substrate to fixedly secure the porous layer onto the substrate.

Abstract: A method of depositing a relatively thin film of bioinert material onto a surgical implant substrate, such as a dental implant. Chemical vapor deposition (CVD) may be used to deposit a layer of tantalum and/or other biocompatible materials onto a solid substrate comprised of an implantable titanium alloy, forming a biofilm-resistant textured surface on the substrate while preserving the material properties and characteristics of the substrate, such as fatigue strength.

Abstract: Methods are provided for manufacturing an orthopedic prosthesis by resistance welding a porous metal layer of the orthopedic prosthesis onto an underlying metal substrate of the orthopedic prosthesis. The resistance welding process involves directing an electrical current through the porous layer and the substrate, which dissipates as heat to cause softening and/or melting of the materials, especially along the interface between the porous layer and the substrate. The softened and/or melted materials undergo metallurgical bonding at points of contact between the porous layer and the substrate to fixedly secure the porous layer onto the substrate.

Abstract: An apparatus and method are provided for manufacturing an orthopedic prosthesis by resistance welding a porous metal layer of the orthopedic prosthesis onto an underlying metal substrate of the orthopedic prosthesis. The resistance welding process involves directing an electrical current through the porous layer and the substrate, which dissipates as heat to cause softening and/or melting of the materials, especially along the interface between the porous layer and the substrate. The softened and/or melted materials undergo metallurgical bonding at points of contact between the porous layer and the substrate to fixedly secure the porous layer onto the substrate.

Abstract: An apparatus and method are provided for manufacturing an orthopedic prosthesis by resistance welding a porous metal layer of the orthopedic prosthesis onto an underlying metal substrate of the orthopedic prosthesis. The resistance welding process involves directing an electrical current through the porous layer and the substrate, which dissipates as heat to cause softening and/or melting of the materials, especially along the interface between the porous layer and the substrate. The softened and/or melted materials undergo metallurgical bonding at points of contact between the porous layer and the substrate to fixedly secure the porous layer onto the substrate.

Abstract: A method of depositing a relatively thin film of bioinert material onto a surgical implant substrate, such as a dental implant. Chemical vapor deposition (CVD) may be used to deposit a layer of tantalum and/or other biocompatible materials onto a solid substrate comprised of an implantable titanium alloy, forming a biofilm-resistant textured surface on the substrate while preserving the material properties and characteristics of the substrate, such as fatigue strength.

Abstract: A method of depositing a relatively thin film of bioinert material onto a surgical implant substrate, such as a dental implant. Chemical vapor deposition (CVD) may be used to deposit a layer of tantalum and/or other biocompatible materials onto a solid substrate comprised of an implantable titanium alloy, forming a biofilm-resistant textured surface on the substrate while preserving the material properties and characteristics of the substrate, such as fatigue strength.

Abstract: A trochanter attachment device can include a plate for attachment to an inner portion of a greater trochanter of a femur, a collar for attaching the plate to a hip implant, and a fastener for securing the collar to a hip implant. The trochanter attachment device can include a groove or other feature for receiving a reinforcing material, such as a wire or a cable, such as to reinforce an attachment of the device to the greater trochanter and/or the hip implant. The trochanter attachment device can include an insert attachable to the plate and configured to attach the plate to the greater trochanter. All or a portion of the plate and/or the insert can include a porous material, such as to promote bone ingrowth of the greater trochanter.

Abstract: A micro-alloyed porous metal is disclosed having an optimized chemical composition to achieve targeted mechanical properties for use as an orthopaedic implant and a cell/soft tissue receptor. The porous metal may achieve a targeted compressive strength and a targeted ductility, for example. These targeted mechanical properties may allow the porous metal to be densified to a low relative density.

Abstract: The present invention relates to improvements in chemical vapor infiltration processes and devices for depositing a biocompatible material onto a porous substrate to form an orthopedic implant. The substrate may be formed of reticulated vitreous foam and coated with tantalum, niobium, tungsten, or other biocompatible materials.

Abstract: Systems and methods for hydrogen out gas of a porous metal scaffold are disclosed. A method can comprise heating a porous metal scaffold for a period of time sufficient to remove at least a portion of a hydrogen concentration from the scaffold, subjecting the porous metal scaffold to a vacuum while heating it, flowing an inert gas through or around the porous metal scaffold while heating it, and enhancing a mechanical property of the porous metal scaffold. Heating of the porous metal scaffold can include maintaining a temperature of the scaffold between 1035° C. and 1065° C., inclusive. A system can comprise a reaction chamber, a heater, a gas feed, and a vacuum apparatus. The heater can be configured to heat the reaction chamber and the porous metal scaffold, while the gas feed and the vacuum apparatus respectively flow inert gas and subject the porous metal scaffold to a vacuum.

Abstract: An orthopedic implant including an articulation portion having a pyrolytic carbon bearing surface and a porous bone on- or in-growth structure, and methods of making the same.

Abstract: An apparatus and method are provided for manufacturing an orthopedic prosthesis by resistance welding a porous metal layer of the orthopedic prosthesis onto an underlying metal substrate of the orthopedic prosthesis. The resistance welding process involves directing an electrical current through the porous layer and the substrate, which dissipates as heat to cause softening and/or melting of the materials, especially along the interface between the porous layer and the substrate. The softened and/or melted materials undergo metallurgical bonding at points of contact between the porous layer and the substrate to fixedly secure the porous layer onto the substrate.

Abstract: A trochanter attachment device can include a plate for attachment to an inner portion of a greater trochanter of a femur, a collar for attaching the plate to a hip implant, and a fastener for securing the collar to a hip implant. The trochanter attachment device can include a groove or other feature for receiving a reinforcing material, such as a wire or a cable, such as to reinforce an attachment of the device to the greater trochanter and/or the hip implant. The trochanter attachment device can include an insert attachable to the plate and configured to attach the plate to the greater trochanter. All or a portion of the plate and/or the insert can include a porous material, such as to promote bone ingrowth of the greater trochanter.

Abstract: A trochanter attachment device can include a plate for attachment to an inner portion of a greater trochanter of a femur, a collar for attaching the plate to a hip implant, and a fastener for securing the collar to a hip implant. The trochanter attachment device can include a groove or other feature for receiving a reinforcing material, such as a wire or a cable, such as to reinforce an attachment of the device to the greater trochanter and/or the hip implant. The trochanter attachment device can include an insert attachable to the plate and configured to attach the plate to the greater trochanter. All or a portion of the plate and/or the insert can include a porous material, such as to promote bone ingrowth of the greater trochanter.

Abstract: The present invention relates to improvements in chemical vapor infiltration processes and devices for depositing a biocompatible material onto a porous substrate to form an orthopedic implant. The substrate may be formed of reticulated vitreous foam and coated with tantalum, niobium, tungsten, or other biocompatible materials.

Abstract: The present invention relates to improvements in chemical vapor infiltration processes and devices for depositing a biocompatible material onto a porous substrate to form an orthopedic implant. The substrate may be formed of reticulated vitreous foam and coated with tantalum, niobium, tungsten, or other biocompatible materials.

Abstract: A micro-alloyed porous metal is disclosed having an optimized chemical composition to achieve targeted mechanical properties for use as an orthopaedic implant and a cell/soft tissue receptor. The porous metal may achieve a targeted compressive strength and a targeted ductility, for example. These targeted mechanical properties may allow the porous metal to be densified to a low relative density.

Abstract: An orthopedic implant including an articulation portion having a pyrolytic carbon bearing surface and a porous bone on- or in-growth structure, and methods of making the same.

Abstract: An apparatus and method are provided for manufacturing an orthopedic prosthesis by resistance welding a porous metal layer of the orthopedic prosthesis onto an underlying metal substrate of the orthopedic prosthesis. The resistance welding process involves directing an electrical current through the porous layer and the substrate, which dissipates as heat to cause softening and/or melting of the materials, especially along the interface between the porous layer and the substrate. The softened and/or melted materials undergo metallurgical bonding at points of contact between the porous layer and the substrate to fixedly secure the porous layer onto the substrate.