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: Various embodiments disclosed relate to an implant. The implant includes a substrate. The implant further includes a monolithic layer comprising a biocompatible metallic material, having at least one of an amorphous and a crystalline microstructure contacting the substrate.

Abstract: One aspect of the present disclosure provides a method of manufacturing an orthopedic prosthesis. This particular method includes providing a porous metal layer (22) positioned against a metal substrate at an interface between the porous metal layer and the metal substrate. Additional steps include providing an electrode (132) and providing an intermediate element or coating positioned between and in contact with the electrode and the porous metal layer where the intermediate element includes tantalum in contact with tantalum of the porous metal layer. In a further step, an electrical current is directed to the interface between the porous metal layer and the metal substrate to bond the porous metal layer to the metal 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: Various embodiments disclosed relate to an implant. The implant includes a substrate. The implant further includes a monolithic layer comprising a biocompatible metallic material, having at least one of an amorphous and a crystalline microstructure contacting 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: Shapeable porous metal implants and methods for use in various procedures are disclosed. The implants can comprise a shell according to some examples. According to one example, the method can include providing a sheet of highly porous metal material having a porosity of between 55% and 90%, and wrapping the sheet of highly porous metal material around at least a first bone of the patient. Further examples can form the sheet intra-operatively to a desired shape. In an example, the porous metal sheet can be formed of tantalum or tantalum alloys.

Abstract: Shapeable porous metal implants and methods for use in various procedures are disclosed. The implants can comprise a shell according to some examples. According to one example, the method can include providing a sheet of highly porous metal material having a porosity of between 55% and 90%, and wrapping the sheet of highly porous metal material around at least a first bone of the patient. Further examples can form the sheet intra-operatively to a desired shape. In an example, the porous metal sheet can be formed of tantalum or tantalum alloys.

Abstract: One aspect of the present disclosure provides a method of manufacturing an orthopedic prosthesis. This particular method includes providing a porous metal layer (22) positioned against a metal substrate at an interface between the porous metal layer and the metal substrate. Additional steps include providing an electrode (132) and providing an intermediate element or coating positioned between and in contact with the electrode and the porous metal layer where the intermediate element includes tantalum in contact with tantalum of the porous metal layer. In a further step, an electrical current is directed to the interface between the porous metal layer and the metal substrate to bond the porous metal layer to the metal substrate.

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: Shapeable porous metal implants and methods for use in various procedures are disclosed. The implants can comprise a shell according to some examples. According to one example, the method can include providing a sheet of highly porous metal material having a porosity of between 55% and 90%, and wrapping the sheet of highly porous metal material around at least a first bone of the patient. Further examples can form the sheet intra-operatively to a desired shape. In an example, the porous metal sheet can be formed of tantalum or tantalum alloys.

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: 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: 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.