Implants with frangible fastener port plugs and methods of manufacturing implants with frangible fastener port plugs

An orthopedic implant comprising:

• a structural body comprising:
• a first surface;
• a second surface opposing the first surface;
• and
• a through-bore extending from the first surface to the second surface, the through-bore having a bore surface;
• wherein the structural body is formed of a porous material;
• a plug disposed in the through-bore, the plug formed of the porous material;
• and
• a frangible connection linking the bore surface and the plug;
• wherein the frangible connection comprises struts extending between the porous material of the structural body and the plug;
• and
• wherein the bore surface is a higher density of material than the struts.

A method of manufacturing an orthopedic implant, the method comprising:

• producing a structural body having a first surface, a second surface opposing the first surface and a through-bore extending from the first surface to the second surface, the through-bore having a bore surface, wherein the structural body is formed of a porous material;
• producing a plug disposed in the through-bore, the plug formed of the porous material;
• and
• producing a frangible connection linking the bore surface and the plug;
• wherein the frangible connection comprises struts extending between the porous material of the structural body and the plug;
• and
• wherein the bore surface is a higher density of material than the struts.