Composite orthopaedic prosthesis and method of making the same

Abstract

An orthopaedic prosthesis includes a femoral component comprising polymeric materials. The polymeric materials may include a polyaromatic ether or a polyacetal. The orthopaedic prosthesis may include a component having an articular layer and a support layer adjacent the articular layer. The support layer may include a reinforcement fiber. The orthopaedic prosthesis may be a knee prosthesis.

1 . A method of making an implantable component for an orthopaedic prosthesis, comprising:
 molding a first layer of polymeric material to second layer of polymeric material to form a composite, and   forming the composite into a predetermined shape of the implantable component, wherein the implantable component has an articular layer and a support layer,   wherein the articular layer comprises a homopolymer and the support layer comprises a polymer and a reinforcement fiber.   
     
     
         2 . The method of  claim 1 , wherein forming the implantable component is an acetabular bearing which is adapted to be implanted into an acetabulum of a patient. 
     
     
         3 . The method of  claim 1 , wherein the implantable component is a glenoid bearing which is adapted to be implanted into a glenoid of a patient. 
     
     
         4 . The method of  claim 1 , wherein the implantable component is a tibial bearing which is adapted to be implanted into a tibia of a patient. 
     
     
         5 . The method of  claim 1 , wherein the homopolymer of the articular layer comprises a polyetheretherketone (PEEK) homopolymer. 
     
     
         6 . The method of  claim 5 , wherein the articular layer further comprises a polysulfone, a polyimide, or a mixture thereof. 
     
     
         7 . The method of  claim 6 , wherein the PEEK is about 75% to about 95% by weight of the articular layer.