Zimmer Gmbh

Carlos Holguin

Steven Seelman

Emmanuel L Uzuyem

Clarence M Panchison

Joseph R Vargas

Cristina Prado Lopez

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.

Resistance welding a porous metal layer to a metal substrate

One aspect of the present disclosure provides a method of manufacturing an orthopedic prosthesis. This particular method includes providing a porous metal layer () positioned against a metal substrate at an interface between the porous metal layer and the metal substrate. Additional steps include providing an electrode () 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.

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Randolph, NJ, United States of America

Carlos Holguin