Rapid manufacturing of porous metal prostheses

Abstract

An orthopaedic prosthesis and a method for rapidly manufacturing the same are provided. The orthopaedic prosthesis includes a solid bearing layer, a porous bone-ingrowth layer, and an interdigitating layer therebetween. A laser sintering technique is performed to manufacture the orthopaedic prosthesis.

What is claimed is: 
     
         1 . A method of rapidly manufacturing an orthopaedic prosthesis having a porous substrate, the porous substrate including an outer surface and a plurality of ligaments that define pores beneath the outer surface, the method comprising the steps of:
 depositing a plurality of metal powder particles onto the outer surface of the porous substrate;   allowing at least a first portion of the plurality of metal powder particles to enter the pores beneath the outer surface of the porous substrate, the first portion of the plurality of metal powder particles being sized to fit within the pores of the porous substrate; and   applying an energy source to the first portion of the plurality of metal powder particles to form solid metal, the solid metal interdigitating into the pores of the porous substrate.