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: An implant can comprise a porous region including a plurality of interconnecting interstitial cells configured to receive bone or biological tissue ingrowth. The porous region can be formed of a first portion, including a first plurality of the interconnecting interstitial cells and having a first density, and a second portion, including a second plurality of the interconnecting interstitial cells and having a second density different than the first density. The plurality of interconnecting interstitial cells can form a framework onto which a material can be disposed in different amounts to provide the first and second densities of the first and second portions, respectively. The second density can be selected and configured to provide greater bone or biological tissue ingrowth than the first density. The first and second density can be selected and configured to substantially match an anisotropic property of a body component the implant is intended to replace or augment.

Abstract: A porous metal implant and method of manufacturing the same are disclosed. The method involves rapidly manufacturing a porous substrate layer-by-layer. The method can include the steps of depositing a first layer of a material and depositing a second layer of the material on top of the first layer. In this manner, a porous substrate having a plurality of ligaments or struts, which define a plurality of pores, can be built. The method can also include coating the porous substrate with a biocompatible metal to strengthen and stabilize the porous substrate for implantation.

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: 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 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.