Abstract: The invention is directed to a molding apparatus, including a cylinder having an interior sidewall and a fluid inlet, and defining an inner cavity. A porous plate is disposed within the inner cavity, and is disposable in a loading position wherein the inner cavity is divided into a fluid flow chamber and a material chamber. A ram having an outside diameter which is less than the diameter of the cylinder interior sidewall is slidable within the cylinder.

Abstract: The invention is directed to a molding apparatus, including a cylinder having an interior sidewall and a fluid inlet, and defining an inner cavity. A porous plate is disposed within the inner cavity, and is disposable in a loading position wherein the inner cavity is divided into a fluid flow chamber and a material chamber. A ram having an outside diameter which is less than the diameter of the cylinder interior sidewall is slidable within the cylinder.

Abstract: A provisional instrument component 1 for evaluating the fit of a corresponding orthopaedic implant. The component 1 is intended and designed to be a disposable, single use provisional instrument component. The provisional instrument component 1 is made of a material which can be sterilized by gamma irradiation, but which provides a visible indicator, such as visible deformation 10, upon resterilization by exposure to a heated environment, thereby discouraging or preventing re-use of the component 1.

Abstract: A provisional instrument component 1 for evaluating the fit of a corresponding orthopaedic implant. The component 1 is intended and designed to be a disposable, single use provisional instrument component. The provisional instrument component 1 is made of a material which can be sterilized by gamma irradiation, but which provides a visible indicator, such as visible deformation 10, upon resterilization by exposure to a heated environment, thereby discouraging or preventing re-use of the component 1.

Abstract: An orthopaedic implant device is formed from, or defined by, a combination of different materials. These devices include a body metal component and a porous metal surface layer for intimate contact with bone and a polymer in the form of a casing that includes adhesive characteristics for attachment to the body metal component and the porous metal layer. The preferred polymer casing is polyaryletherketone.

Abstract: A bone implant includes a nonmetallic core and a metallic porous surface secured to the nonmetallic core. The nonmetallic core is designed to closely approximate the modulus of elasticity for bone and the metallic porous surface is intimately engaged with bone to enhance bone growth into the metallic porous surface.

Abstract: A composite implant prosthesis comprising a core constructed from a plurality of carbon fibers, a first casing formed from a braided sheath of carbon fibers and a second casing enclosing the core and first casing to define an outer surface contour for the composite implant prosthesis. The method for constructing the composite implant prosthesis includes the steps of pultruding the core from a polymer impregnated tow, braiding the first casing to the pultruded core and applying the second casing thereto. The pultruding and braiding steps are performed in a continuous process while the second casing is applied to a discrete element formed from the core.

Abstract: A composite implant prosthesis comprising a core constructed from a plurality of carbon fibers, a first casing formed from a braided sheath of carbon fibers and a second casing enclosing the core and first casing to define an outer surface contour for the composite implant prosthesis. The method for constructing the composite implant prosthesis includes the steps of pultruding the core from a polymer impregnated tow, braiding the first casing to the pultruded core and applying the second casing thereto. The pultruding and braiding steps are performed in a continuous process while the second casing is applied to a discrete element formed from the core.

Abstract: An orthopedic device formed from a composite material which is reinforced with continuous filament carbon fibers to provide the material with high flexural strength, hydrolytic stability and a medical grade quality. A preferred embodiment of the orthopedic device is a hip joint prosthesis in which the stem and spherical head of the prosthesis can be formed from a composite block. In the alternative, the stem alone can be formed from the block and a head of another material attached to one end of the stem. One embodiment of the method includes first forming a sheet of carbon fibers by wrapping carbon fiber tows spirally around a drum after passing the tows through a thermoplastic resin which serves as a bonding agent. Then, rectangular pieces of the carbon fiber-polymer sheet are combined one with another to form a stack. Pressure is exerted on the stack in the presence of heat to form the composite block. Following the formation of the block, the block is machined to form the desired orthopedic device.