Systems and methods for manufacturing orthopedic prostheses

An orthopedic prosthesis mold system, comprising:

• a first housing including a first cavity therein shaped to form a portion of a tibial knee joint prosthesis;
• a second housing coupled to the first housing, the second housing including a second cavity therein shaped to form a portion of a tibial knee joint prosthesis;
• a plurality of spacing elements positionable within the second cavity of the second housing configured to selectively adjust a height of a prosthesis molded therein;
• a first shell element configured to receive at least a portion of the first housing therein;
• a second shell element configured to receive at least a portion of the first housing therein;
• a connection element releasably engageable to the first and second shell elements to prevent separation of the first shell element from the second shell element;
• and
• wherein the first and second shell elements are constructed from a material having a hardness between Shore 40D and 80D.

An orthopedic prosthesis mold system, comprising:

• a first housing including a first cavity therein shaped to form a portion of a hip stem prosthesis;
• a second housing coupled to the first housing, the second housing including a second cavity therein shaped to form a portion of a hip stem prosthesis;
• a first shell element configured to receive at least a portion of the first housing therein;
• a second shell element configured to receive at least a portion of the first housing therein;
• a connection element releasably engageable to the first and second shell elements to prevent separation of the first shell element from the second shell element;
• and
• wherein the first and second housings are constructed from a material having a first hardness, and wherein the first and second shell elements are constructed from a material having a second hardness greater than the first hardness.