Implant components and methods

Abstract

Systems, devices, and methods are provided for orthopedic implants. The implants may include a base member, such as an acetabular shell or an augment, that is configured to couple with an augment, flange cup, mounting member, or any other suitable orthopedic attachment.

We claim: 
     
         1 . An implantable orthopedic device, comprising:
 an implant having a porous surface defining a plurality of pores sized to accommodate bone-ingrowth into the implant, the implant further including a plurality of protrusions extending from the porous surface and which rise above the porous surface;   wherein the plurality of protrusions are configured to frictionally engage a bone surface without interfering with bone ingrowth into the plurality of pores;   wherein the implant is a metallic implant; and   wherein the implant comprises a surface profile that is formed using a rapid manufacturing process.   
     
     
         2 . The device of  claim 1 , wherein the rapid manufacturing process comprises a 3D printing process. 
     
     
         3 . The device of  claim 1 , wherein the rapid manufacturing process comprises a selective laser sintering process. 
     
     
         4 . The device of  claim 1 , wherein the protrusions are blunt. 
     
     
         5 . The device of  claim 1 , wherein the protrusions rise above the porous surface to a height between about 50 μm and about 2,000 μm. 
     
     
         6 . The device of  claim 5 , wherein the height is between about 100 μm and about 1,100 μm. 
     
     
         7 . The device of  claim 1 , wherein the implant comprises a solid non-porous portion. 
     
     
         8 . The device of  claim 7 , wherein the solid non-porous portion of the implant comprises a solid outer surface portion. 
     
     
         9 . The device of  claim 8 , wherein the solid outer surface portion is configured for articulation with another implant component. 
     
     
         10 . The device of  claim 1 , wherein the protrusions occupy approximately 10% to approximately 60% of the porous surface. 
     
     
         11 . The device of  claim 1 , wherein the pores have a size of approximately 50 microns to 1000 microns. 
     
     
         12 . The device of  claim 1 , wherein the protrusions have a concentration between about 0.25 protrusions per square millimeter and about 6 protrusions per square millimeter. 
     
     
         13 . An implantable orthopedic device, comprising:
 an implant having a porous surface defining a plurality of pores sized to accommodate bone-ingrowth into the implant, the implant further including a plurality of protrusions extending from the porous surface and which rise above the porous surface; wherein the plurality of protrusions are configured to frictionally engage a bone surface without interfering with bone ingrowth into the plurality of pores;   wherein the implant comprises a surface profile that is formed using a rapid manufacturing process; and   wherein the protrusions rise above the porous surface to a height between about 50 μm and about 2,000 μm.   
     
     
         14 . The device of  claim 13 , wherein the protrusions are blunt. 
     
     
         15 . The device of  claim 13 , wherein the height is between about 100 μm and about 1,100 μm. 
     
     
         16 . The device of  claim 13 , wherein the implant comprises a solid non-porous portion. 
     
     
         17 . The device of  claim 16 , wherein the solid non-porous portion of the implant comprises a solid outer surface portion. 
     
     
         18 . The device of  claim 17 , wherein the solid outer surface portion is configured for articulation with another implant component. 
     
     
         19 . The device of  claim 13 , wherein the protrusions occupy approximately 10% to approximately 60% of the porous surface. 
     
     
         20 . The device of  claim 13 , wherein the pores have a size of approximately 50 microns to 1000 microns. 
     
     
         21 . The device of  claim 13 , wherein the protrusions have a concentration between about 0.25 protrusions per square millimeter and about 6 protrusions per square millimeter. 
     
     
         22 . An implantable orthopedic device, comprising:
 an implant having a porous surface defining a plurality of pores sized to accommodate bone-ingrowth into the implant, the implant further including a plurality of protrusions extending from the porous surface and which rise above the porous surface;   wherein the plurality of protrusions are configured to frictionally engage a bone surface without interfering with bone ingrowth into the plurality of pores;   wherein the protrusions rise above the porous surface to a height between about 50 μm and about 2,000 μm; and   wherein the implant comprises a surface profile that is formed using a selective laser sintering process