Methods of forming implants suitable for soft tissue repair

A method of forming an implantable web for soft tissue repair comprising the steps of:

• a) providing a substrate onto a movable tray,
• b) laying a plurality of laid yarns onto a first side of a substrate via a laying guide element, wherein the laid yarns includes a plurality of radial yarns and a plurality of spiral yarns, each of the plurality of radial yarns extending in a radial direction from a center of a central area of the implantable web, and each of the plurality of spiral yarns turning around the central area and extending between the plurality of radial yarns, the spiral yarns connecting neighboring radial yarns
• c) threading a needle including a first threading yarn from the first side of the substrate through the substrate to a second side of the substrate and around a second threading yarn,
• d) returning the needle to the first side of the substrate with a portion of the first and second threading yarns to form a locking stitch around at least one of the plurality of laid yarns and locking the laid yarn into position on the substrate and relative to other laid yarns,
• e) advancing some combination of the movable tray, substrate, laying guide element, or needle to extend the first and second threading yarns along the laid yarn a certain length before repeating steps c) and d), wherein the threading yarns are smaller in cross-sectional size than the radial yarns, which are smaller in cross-sectional size than the spiral yarns.