Multi-layered implant

Abstract

A multi-layered implant and methods of forming the multi-layered implant are disclosed. The multi-layered implant includes a Metal Injection Molded body comprising a titanium alloy, a porous coating layer on a first surface of the Metal Injection Molded body, and a zirconium alloy layer on a second surface of the Metal Injection Molded body. The first surface and the second surface are on opposite sides of the Metal Injection Molded body. A zirconia layer may be formed over the zirconium alloy layer. The porous coating may be a titanium-based porous coating.

What is claimed is: 
     
         1 . A multi-layered implant, comprising:
 a Metal Injection Molded body comprising a titanium alloy;   a porous coating layer on a first surface of the Metal Injection Molded body; and   a zirconium alloy layer on a second surface of the Metal Injection Molded body, the first surface and the second surface being on opposite sides of the Metal Injection Molded body.   
     
     
         2 . The multi-layered implant of  claim 1 , wherein the porous coating layer comprises a titanium-based porous coating. 
     
     
         3 . The multi-layered implant of  claim 1 , further comprising a zirconia layer over the zirconium alloy layer. 
     
     
         4 . The multi-layered implant of  claim 1 , wherein the zirconium alloy layer comprises a zirconium-niobium alloy. 
     
     
         5 . The multi-layered implant of  claim 1 , wherein the multi-layered implant is a knee implant, a shoulder implant, an ankle implant, a spine implant, a disc implant, or a hip implant. 
     
     
         6 . A knee implant, comprising:
 a titanium alloy substrate;   a porous coating layer on a first surface of the titanium alloy substrate;   a zirconium alloy layer on a second surface of the titanium alloy substrate, the first surface and the second surface being on opposite sides of the titanium alloy substrate; and   a zirconia layer over the zirconium alloy layer.   
     
     
         7 . The knee implant of  claim 6 , wherein the porous coating layer comprises titanium-based porous coating. 
     
     
         8 . The knee implant of  claim 6 , wherein the zirconium alloy layer comprises a zirconium-niobium alloy. 
     
     
         9 . A method of manufacturing a multi-layered implant, the method comprising:
 providing a Metal Injection Molded body comprising a titanium alloy;   applying a porous coating on a first surface of the Metal Injection Molded body to form a porous coating layer, and a zirconium alloy on a second surface of the Metal Injection Molded body to form a zirconium alloy layer, the first surface and the second surface being on opposite sides of the Metal Injection Molded body; and   oxidizing the zirconium alloy layer to form a zirconia layer over the zirconium alloy layer.   
     
     
         10 . The method of  claim 9 , wherein providing the Metal Injection Molded body comprises receiving the Metal Injection Molded body. 
     
     
         11 . The method of  claim 9 , wherein providing the Metal Injection Molded body comprises molding the Metal Injection Molded body. 
     
     
         12 . The method of  claim 9 , wherein applying the zirconium alloy on the second surface of the Metal Injection Molded body comprises over-molding the zirconium alloy on the second surface of the Metal Injection Molded body to form the zirconium alloy layer. 
     
     
         13 . The method of  claim 9 , further comprising:
 sintering the Metal Injection Molded body; and   hot isostatic pressing the Metal Injection Molded body.   
     
     
         14 . The method of  claim 13 , wherein sintering the Metal Injection Molded body comprises:
 sintering the porous coating on the first surface of the Metal Injection Molded body; and   sintering the zirconium alloy on the second surface of the Metal Injection Molded body.   
     
     
         15 . The method of  claim 9 , further comprising polishing the zirconium alloy layer. 
     
     
         16 . The method of  claim 15 , wherein polishing the zirconium alloy layer comprises applying an abrasive finishing process to the zirconium alloy layer. 
     
     
         17 . The method of  claim 9 , further comprising heat treating the zirconium alloy layer. 
     
     
         18 . The method of  claim 9 , wherein oxidizing the zirconium alloy layer comprises heating the zirconium alloy layer in an oxidative environment to form the zirconia layer. 
     
     
         19 . The method of  claim 9 , further comprising mechanically finishing the zirconia layer. 
     
     
         20 . The method of  claim 9 , wherein the zirconium alloy comprises a zirconium-niobium alloy.