Abstract: Composite materials formed from bone bioactive glass or ceramic fibers and structural fibers are disclosed. In preferred embodiments, a braid or mesh of interwoven bone bioactive glass or ceramic fibers and structural fibers is impregnated with a polymeric material to provide a composite of suitable biocompatibility and structural integrity. Most preferably, the mesh or braid is designed so that the bioactive fibers are concentrated at the surface of the implant to create a surface comprised of at least 30% bioactive material, thereby providing enhanced bone ingrowth. The interweaving between the bone bioactive glass or ceramic fibers and the core of structural fibers overcomes the problems found in prior composite systems where the bioactive material delaminates from the polymer. Preferred bioactive materials include calcium phosphate ceramics and preferred structural fibers include carbon fibers. Improved prosthetic implants and methods of affixing an implant are thus also disclosed.

Abstract: Orthopaedic implants exhibiting improved fatigue strength are disclosed. By forming a plurality of nodules on the surface of an implant and depositing a porous coating onto the surface of these nodules, the fatigue strength of implants such as those made from .alpha.+.beta. titanium alloys, e.g., Ti-6Al-4V alloy is substantially improved. The present invention provides a novel geometry which substantially reduces the stress concentration factor created by the interfacial geometry of conventional porous coatings. Methods of manufacturing porous coated orthopaedic implants are also disclosed.

Abstract: Orthopaedic implants exhibiting improved fatigue strength are disclosed. By forming a plurality of nodules on the surface of an implant and depositing a porous coating onto the surface of these nodules, the fatigue strength of implants such as those made from .alpha.+.beta. titanium alloys, e.g., Ti-6Al-4V alloy is substantially improved. The present invention provides a novel geometry which substantially reduces the stress concentration factor created by the interfacial geometry of conventional porous coatings. Methods of manufacturing porous coated orthopaedic implants are also disclosed.

Abstract: A sintered, shaped long-life dental implant or osseous prosthesis adapted for implantation into a human or animal body with chemical bonding to bone tissue. The implant or prosthesis is the result of sintering of a shaped mass of bioglass particles at or above a temperature softening the bioglass particles to form a bioreactive material having a composition comprising, by weight, 5-14% Na.sub.2 O, 0-12% P.sub.2 O.sub.5, 49-57% SiO.sub.2, and balance, no more than 33% CaO+CaF.sub.2, with the bioreactive material containing 0.5-7% CaF.sub.2. The implant or prosthesis has limited reactivity with bone tissue and a coefficient of expansion less than 10.sup.-5 K.sup.-1 from 0.degree. to 100.degree. C.

Abstract: Process for the restoration of an osseous defect or deficiency by filling with osseous tissue with the aid of a bioreactive granular material causing an osteostimulation, the particles of said granular material being disintegrated from the inside, dissolved and replaced by osseous tissue, the granular material containing 40 to 55% SiO.sub.2, 10 to 32% Na.sub.2 O, 0 to 12% P.sub.2 O.sub.5 and 10 to 32% CaO, which has a grain size distribution between 280 and 425 .mu.m, sharp edges, an irregular profile and surface microdefects or microcracks.

Abstract: Improved ceramics which promote bone ingrowth are disclosed. The coating of the present invention consists essentially of oxyhydroxyapatite, and alpha- and beta-tricalcium phosphate. Methods of making and using the ceramics are also disclosed. The present invention uses a microscopically powdered form of calcium-phosphate materials and electrophoretic deposition to create ceramics having significantly higher dissolution rates than previous materials. By agitating the electrophoretic solution, agglomeration is prevented and a uniform coating is achieved. Thus, the present invention presents both improved ceramic materials and novel methods of depositing them uniformly upon metal surfaces, such as titanium wire mesh.

Abstract: A method is disclosed for preparing an improved bioreactive material of the glass or partially crystallized glass type for bone prostheses or dental implants, which can be welded to bone tissue by chemical bonding. The material consisting essentially of, by weight, 5 to 14% Na.sub.2 O, 0 to 12% P.sub.2 O.sub.5, 49 to 57% SiO.sub.2, and balance, no more than 33% CaO+CaF.sub.2, the material containing 0.5 to 7% CaF.sub.2, and is prepared by a method comprising the steps of preparing a mixture of powders constituting a precursor of the material made of carbonates, phosphates, silica, oxides and fluorides, melting, homogenizing, casting and cooling the mixture to obtain an intermediate, non-crystallized glass, optionally annealing, and then grinding, either pressing the non-crystallized ground glass obtained cold to shape it, then sintering naturally or under a load after degassing, or sintering under a load directly after degassing, then cooling and optionally polishing or machining.

Abstract: Titanium or other biocompatible metal fibers having a diameter of from about 20 to about 200 .mu.m, a length of from about 2 to 50 mm and a length-to-diameter ratio of at least about 100 are formed into a flexible and deformable mass, for example, a sheet, of interlocked fibers, which may be sintered for additional coherence, to a thickness of from about 0.5 to 30 mm. The amount of fibers is such that the sheet has a voids volume of at least 65%, preferably about 90%. The diameter of the pores of the porous sheet are at least about 150 .mu.m such that bony tissue can grow in the pores. These porous sheets are highly malleable without loss of structural integrity or pore size distribution. Accordingly, the porous metal fiber mesh sheets are useful for stabilizing prosthetic devices or for general repair of defective bone structures.

Abstract: Improved ceramics which promote bone ingrowth are disclosed. The coating of the present invention consists essentially of oxyhydroxyapatite, and alpha- and beta-tricalcium phosphate. Methods of making and using the ceramics are also disclosed. The present invention uses a microscopically powdered form of calcium-phosphate materials and electrophoretic deposition to create ceramics having significantly higher dissolution rates than previous materials. By agitating the electrophoretic solution, agglomeration is prevented and a uniform coating is achieved. Thus, the present invention presents both improved ceramic materials and novel methods of depositing them uniformly upon metal surfaces, such as titanium wire mesh.

Abstract: The distribution of short, fine, reinforcing fibers homogeneously throughout surgical bone cement is accomplished by adding the fibers in the form of bundles of several hundred fibers with the fibers bonded to each other with an adhesive binder that is soluble in the liquid monomer component of the bone cement. The fiber bundles are either premixed with the powdery polymer bead component of the bone cement followed by addition of the liquid monomer or the polymer and liquid are premixed into a viscous liquid and the fiber bundles are gradually added with stirring to the viscous liquid. In either case, as the adhesive binder dissolves in the liquid monomer the individual fibers are freed and continued stirring mixes the fibers homogeneously throughout the cement mass.

Abstract: A carefully controlled amount of hydrogen is diffused into titanium or its alloys at an elevated temperature above the transformation temperature. After the elevated temperature is maintained for an approprate duration of time, eutectoid transformation is performed in an inert atmosphere, again for an appropriate period of time, during which or alternatively after which the hydrogen is removed and the metal cooled to room temperature. A sintered titanium alloy component of the type intended for use as a joint replacement subjected to such a treatment displays a fatigue strength which is noticeably improved over a similar article with an equiaxed or lamellar microstructure.

Abstract: Titanium or other biocompatible metal fibers having a diameter of from about 20 to about 200 .mu.m, a length of from about 2 to 50 mm and a length-to-diameter ratio of at least about 100 are formed into a flexible and deformable mass, for example, a sheet, of interlocked fibers, which may be sintered for additional coherence, to a thickness of from about 0.5 to 30 mm. The amount of fibers is such that the sheet has a voids volume of at least 65%, preferably about 90%. The diameter of the pores of the porous sheet are at least about 150 .mu.m such that bony tissue can grow in the pores. These porous sheets are highly malleable without loss of structural integrity or pore size distribution. Accordingly, the porous metal fiber mesh sheets are useful for stabilizing prosthetic devices or for general repair of defective bone structures.