Bristol-myers Squibb Compnay

Zimmer Gmbh

Richard C Compton

Clarence M Panchison

Michael S Hawley

William B Clarke

Jay B Moore

Leslie N Gilbertson

Steven C Kitch

Richard B Cwik

David M Blakemore

Larry S Bender

Steven M Humphrey

Kris K Merchant

Tim A Mosher

Robin J Reed

Ravindranath H Shetty

Leslie N Gibertson

A method of forming an orthopedic implant having a porous surface layer thereon. A mask includes a cut-out configured to receive a portion of the implant therein. The implant is placed within the cut-out and thereby masked. A water soluble binder solution is sprayed onto at least a part of the unmasked portion of the implant using a sprayer, thereby forming a binder layer on the implant. The binder solution includes water, ethanol, gelatin, glycerin, and a colorant. A porous layer including a plurality of metallic particles is contacted with the binder layer. The porous layer is bonded with the surface of the implant with a sintering process.

Method of making an orthopaedic implant having a porous surface

A method of forming an orthopaedic implant having a porous surface layer thereon. A mask includes a cut-out configured to receive a portion of the implant therein. The implant is placed within the cut-out and thereby masked. A water soluble binder solution is sprayed onto at least a part of the unmasked portion of the implant using a sprayer, thereby forming a binder layer on the implant. The binder solution includes water, ethanol, gelatin, glycerin, and a colorant. A porous layer including a plurality of metallic particles is contacted with the binder layer. The porous layer is bonded with the surface of the implant with a sintering process.

A method of making an orthopaedic implant includes the step of forming an orthopaedic implant body which has a supporting surface. A porous metal pad is formed to fit the supporting surface of the body. The porous metal pad is clamped and/or adhesively bonded to the supporting surface. A laser beam is coupled between the porous metal pad and the implant body at a plurality of locations so as to form a coalescence of metal between the porous metal pad and the body.

Method of making an orthopaedic implant having a porous metal pad

An orthopaedic implant is forged from a metallic body consisting of a cobalt-chromium alloy. The forged implant is descaled by blasting the implant with a particulate blasting agent at a momentum which is sufficient to remove scale formed on the implant during the forging step but insufficient to otherwise cause major structural surface deformation to the implant. The descaled implant is electro-chemical polished by submersing the implant in an acid bath having a temperature of between approximately 80.degree. F. and 90.degree. F. The acid bath includes approximately 45% sulfuric acid and 50% phosphoric acid. Direct current electrical power ranging between approximately 10 volts D.C. and 13 volts D.C. is applied to the implant. The polished implant is ultrasonically cleaned. The implant is inspected with a fluorescent penetrant to determine whether surface defects exist in the implant.

Process of manufacturing a cobalt-chromium orthopaedic implant without

A method of forming a cast orthopaedic implant having a porous surface layer is disclosed. The method includes placing a porous layer on a wax replica of the implant such that a portion of the pores of the layer are filled with the wax material. The wax replica and porous surface layer are coated by a ceramic material consistent with investment casting technology. The ceramic material fills the remainder of the pores of the porous layer. After the ceramic material is solidified, the wax material is melted away leaving a cavity within the ceramic material. The pores once filled by wax are now exposed and extend into the cavity. A molten metal is poured into the cavity and partially melts the exposed porous layer to form a melt bond with the molten metal. When the metal is cooled, the ceramic material is stripped away exposing the portion of the porous layer previously filled with the ceramic medium.

Cast orthopaedic implant and method of making same

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Warsaw, IN, United States of America

Richard C Compton