High Strength Injection Molded Orthopedic Devices

Abstract

High strength implantable devices having complex surfaces are injection molded from powder metal wherein the surface is defined by a monolithic insert made by additive manufacturing. The insert defines the surface texture of the device and may also include a portion to form an ingrowth texture and a portion to form a substrate interface texture. The tensile bond strength of the texture is 20 Mega Pascal or greater.

What is claimed is: 
     
         1 . An textured implantable device comprising: a fixation texture comprising an array of protruding undercut features, an ingrowth portion with a porosity between 60 and 85 percent, and an interface region to a dense portion of the device, wherein the tensile bond strength of the ingrowth portion is at least 50 Mega Pascal. 
     
     
         2 . The implantable device of  claim 1 , manufactured by powder metal injection molding wherein the fixation texture, ingrowth portion and interface region are formed by a monolithic mold insert.