Additive manufactured femoral components

Abstract

Described is a femoral component of a prosthetic hip implant. The femoral component can include: a neck portion; and a stem portion including a proximal end and a distal end. The neck portion extends from the proximal end, and the stem portion comprises a first solid portion and at least one additional portion including at least one of a hollow portion, a porous portion, and a second solid portion comprised of a different solid material from a solid material of the first solid portion. The first solid portion and the at least one additional portion are in a predetermined configuration. The femoral component comprises a unitary component that is formed by additive manufacturing of the femoral component from a 3D model of the femoral component.

1 . A femoral component of a prosthetic hip implant, the femoral component comprising:
 a neck portion; and   a stem portion including a proximal end and a distal end, wherein the neck portion extends from the proximal end, and the stem portion comprises at least two distinct longitudinal stem segments including:
 a solid segment; and 
 a hybrid segment including an outer portion defining an outer surface of the hybrid segment and at least one of a hollow core portion, a porous core portion, or a solid core portion; 
   wherein the femoral component comprises a unitary component that is formed by additive manufacturing of the femoral component from a 3D model of the femoral component.   
     
     
         2 . The femoral component of  claim 1 , wherein the outer portion of the hybrid segment is porous. 
     
     
         4 . The femoral component of  claim 2 , wherein the hybrid segment includes a solid core portion. 
     
     
         5 . The femoral component of  claim 2 , wherein the hybrid segment includes a porous core portion. 
     
     
         6 . The femoral component of  claim 2 , wherein the hybrid segment includes at least two of a hollow core portion, a porous core portion, or a solid core portion. 
     
     
         7 - 8 . (canceled) 
     
     
         9 . The femoral component of  claim 1 , wherein the stem portion is tapered from the proximal end to the distal end. 
     
     
         10 . The femoral component of  claim 1 , wherein the stem portion has a cross-sectional profile that is trapezoidal-shaped, rectangular-shaped, oval-shaped, circular-shaped, or teardrop-shaped. 
     
     
         11 . The femoral component of  claim 1 , wherein the stem portion includes a plurality of longitudinally extending flutes along an outer surface of the solid segment and the outer surface of the hybrid segment. 
     
     
         12 . A prosthetic hip implant comprising:
 a femoral ball; and   a femoral component comprising:
 a neck configured to connect to the femoral ball; and 
 a stem including a proximal end and a distal end, wherein the neck extends from the proximal end, and the stem comprises a solid segment and hybrid segment, the hybrid including at least two of a hollow portion, a porous portion, or a solid portion; 
   wherein the femoral component comprises a unitary component that is formed by additive manufacturing of the femoral component from a 3D model of the femoral component.   
     
     
         13 . The prosthetic hip implant of  claim 12 , further comprising an acetabular shell. 
     
     
         14 - 20 . (canceled) 
     
     
         21 . The prosthetic hip implant of  claim 12 , wherein the hybrid segment includes a porous portion, the porous portion defining an outer surface of the hybrid segment. 
     
     
         22 . The prosthetic hip implant of  claim 21 , wherein the hybrid segment further includes a solid portion that is circumscribed by the porous portion. 
     
     
         23 . The prosthetic hip implant of  claim 22 , wherein the hybrid segment further includes a hollow portion that is circumscribed by the solid portion. 
     
     
         24 . The prosthetic hip implant of  claim 22 , wherein the hybrid segment further includes a second porous portion that is circumscribed by the solid portion. 
     
     
         25 . The prosthetic hip implant of  claim 21 , wherein the hybrid segment further includes a second porous portion that is circumscribed by the porous portion. 
     
     
         26 . The prosthetic hip implant of  claim 25 , wherein the hybrid segment further includes a hollow portion that is circumscribed by the second porous portion. 
     
     
         27 . The prosthetic hip implant of  claim 25 , wherein the hybrid segment further includes a solid portion that is circumscribed by the second porous portion. 
     
     
         28 . The prosthetic hip implant of  claim 12 , wherein the stem is tapered from the proximal end to the distal end. 
     
     
         29 . A femoral component of a prosthetic hip implant, the femoral component comprising:
 a solid proximal section including a smooth outer surface;   a solid distal section including a smooth outer surface; and   a hybrid middle section disposed between the proximal section and the distal section, the middle section including a circumferential porous portion defining an outer surface of the middle section, an inner cavity defined by an inner circumferential wall of the circumferential porous portion, and an I-beam-shaped solid segment disposed within the inner cavity, wherein the circumferential porous portion is permeated with interconnected interstitial pores structured to promote at least one of bone ongrowth or bone ingrowth;   wherein the femoral component comprises a unitary component that is formed by additive manufacturing from a 3D model of the femoral component.