Solid Freeform Fabrication of Implant Components

Abstract

Disclosed are designs, methods and systems for manufacturing implants, implant components, features of implant components, and/or related tools using solid freeform fabrication or additive metals technologies.

What is claimed is: 
     
         1 . A tibial implant component, the tibial implant component comprising:
 a tibial tray; and   at least one anchoring structure extending distally from a bone-facing surface of the tibial tray, the anchoring structure having a proximal end and a distal end separated by a first length,   wherein the tibial tray is configured to include a substantially solid structure,   wherein the bone-facing surface of the tibial tray further includes porous surface features configured to promote bone ingrowth,   wherein a proximal portion of the anchoring structure consists of two or more cavities adjacent to the bone facing surface of the tibial tray, and   wherein the tibial tray and the anchoring structure are integral and formed of a single material.   
     
     
         2 . The tibial implant component of  claim 1 , wherein the anchoring structure comprises an anchoring peg. 
     
     
         3 . The tibial implant component of  claim 2 , wherein the anchoring structure further comprises one or more wings configured to provide rotational stability to the tibial tray. 
     
     
         4 . The tibial implant component of  claim 3 , further comprising two or more peripheral anchoring pegs extending distally from the bone-facing surface of the tibial tray, the peripheral anchoring pegs each having a proximal end and a distal end separated by a second length, wherein the second length is smaller than the first length. 
     
     
         5 . An implant component comprising:
 a first implant portion having a substantially solid structure, the first implant portion having a bone-facing surface;   an anchoring structure extending distally from the bone-facing surface of the first implant portion; and   a second implant portion having a substantially porous structure, the second implant portion distal to the first implant portion,   wherein a proximal portion of the anchoring structure consists of two or more cavities adjacent to the second implant portion, and   wherein the first implant portion and the anchoring peg are integral and formed of a single material.   
     
     
         6 . The implant component of  claim 5 , wherein the anchoring structure comprises an anchoring peg. 
     
     
         7 . The implant component of  claim 6 , wherein the anchoring structure further comprises one or more wings configured to provide rotational stability to the implant component. 
     
     
         8 . The implant component of  claim 5 , wherein at least one dimension of the implant component is based on patient-specific information. 
     
     
         9 . The implant component of  claim 5 , wherein at least one dimension of the anchoring peg is based on patient-specific information.