Abstract: An orthopaedic implant comprising a cast metal base member having an outer surface and an ingrowth surface comprising a plurality of attachment spacer elements of unequal lengths integrally cast with said base member and a metal attachment element integrally cast with said spacer elements, said attachment element having connecting elements extending between said spacer elements to allow attachment of the bone to occur between an underside of said connecting elements and the outer surface of said base member. The invention also consists of a method for preparing such an implant, wherein the spacer elements are of equal or unequal length, which comprises inserting a preformed ceramic pattern for the ingrowth surface into a die for the implant, injecting a meltable material in its molten state into the die at a temperature below the melting temperature of the ceramic to fill the holes and grooves of the pattern.

Abstract: A prosthetic part for use as an orthopaedic implant has a cast metal base member and a tissue ingrowth surface spaced outwardly therefrom. The tissue ingrowth surface is in the form of a cast metal lattice element which covers at least a part of the outer surface of the base member. The cast metal lattice element is cast simultaneously and integrally with the base member from the same metal. This metal may be any well known castable material for orthopaedic implants such as Vitallium or titanium. The lattice element is in the form of a grid-like mesh which includes spaced members cast integrally with the wire mesh and the base member to space the lattice element a predetermined distance above the prosthesis surface. An investment casting technique wherein a meltable material is coated with a ceramic casting shell is utilized to produce the integrally cast orthopaedic implant and tissue ingrowth surface.

Abstract: A diffusion and brazing method of bonding honeycomb core material to its facing sheets wherein the core and facing sheets have a predetermined configuration and either the facing sheets or the core edges have had deposited thereon a laminate formed of diffusion bridge or braze alloy material. First, the faying surfaces of the facing sheets and the core are positioned together with the core located between the facing sheets to form the assembly. Secondly, a male plug is inserted into the interior of the assembly wherein the dimensions of the male plug are slightly smaller than the interior dimensions of the asembly and wherein the male plug is formed from a metal having a thermal coefficient of expansion greater than that of the material of the facing sheets and core.