Prosthesis with composite component

A joint prosthesis comprising:

• a first component having an articulation surface;
• a bearing having an articulation surface shaped to bear against the articulation surface of the first component and an opposite surface;
• and
• a composite component having a mounting surface, a bone-engaging surface and an extension extending out from the bone-engaging surface opposite the mounting surface;
• wherein:
• the opposite surface of the bearing and the mounting surface of the composite component have complementary locking features for mounting the bearing on the composite component;
• the extension is configured for stabilizing the composite component when implanted in a bone of a patient;
• the composite component includes a porous polymer portion, a solid polymer portion and a metal reinforcing portion;
• the solid polymer portion defines the mounting surface of the composite component;
• the porous polymer portion defines the bone engaging surface of the composite component;
• and
• the metal reinforcing portion is positioned between and spaced from the mounting surface and the bone-engaging surface.
• the solid polymer portion, porous polymer portion and metal reinforcing portion are bonded together.

A knee prosthesis comprising:

• a femoral component having a medial condyle surface and a lateral condyle surface;
• a bearing having a distal surface and a proximal surface including (i) a medial bearing surface configured to articulate with the medial condyle surface of the femoral component, and (ii) a lateral bearing surface configured to articulate with the lateral condyle surface of the femoral component;
• and
• a tibial tray secured to the bearing, the tibial tray having a platform having (i) a proximal surface;
• (ii) a distal surface opposite the proximal surface;
• and (iii) an extension extending from the distal surface of the platform to a distal end along an axis intersecting the distal surface, the extension having an axial length and an exterior surface including a proximal exterior surface adjacent to the distal surface of the platform and a distal exterior surface, the distal exterior surface proximally extending from the distal end for at least part of the axial length of the extension;
• wherein:
• the tibial tray comprises a composite including a solid polymer portion and a porous portion;
• the solid polymer portion of the tibial tray defines the proximal surface of the platform and bears against the distal surface of the bearing;
• the solid polymer portion extends from the proximal surface of the platform into the extension;
• the solid polymer portion defines the distal exterior surface of the extension;
• the solid polymer portion is secured to the porous portion of the tibial tray;
• the porous portion of the tibial tray has a greater porosity than the femoral component;
• and
• the porous portion of the tibial tray defines the distal surface of the platform.

An ankle knee prosthesis comprising:

• a distal tibial component having a (i) proximal bone-engaging surface;
• (ii) a distal mounting surface;
• and (iii) an extension extending from the proximal bone-engaging surface to a proximal end along an axis intersecting the proximal surface, the extension having an axial length and an exterior surface including a distal exterior surface adjacent to the proximal bone-engaging surface of the distal tibial component and a proximal exterior surface, the proximal exterior surface proximally extending from the proximal end for at least part of the axial length of the extension;
• a bearing having an articululation surface and a mounting surface;
• and
• a talar component having an articulation surface and a bone-engaging surface;
• wherein:
• the distal tibial component comprises a composite including a solid polymer portion and a porous portion;
• the solid polymer portion of the distal tibial component defines the proximal end of the extension and the mounting surface of the distal tibial component and bears against the mounting surface of the bearing;
• the solid polymer portion of the distal tibial component is secured to the porous portion of the tibial component;
• and
• the porous portion of the tibial component defines the proximal bone-engaging surface of the tibial component and the proximal exterior surface of the extension.

A method of making a tibial tray component of a knee prosthesis comprising the steps of:

• providing a porous base having a proximal surface, a distal surface and an extension extending distally from the proximal surface to a distal end, the extension having an opening at the distal end, the porous base having an interior surface extending from the proximal surface to the opening at the distal end of the extension;
• providing a quantity of fiber-reinforced polyetheretherketone (PEEK) material;
• and
• molding the fiber-reinforced polyetheretherketone (PEEK) material to the porous base so that the fiber-reinforced polyetheretherketone (PEEK)overlies the proximal surface of the porous base and so that the fiber reinforced polyetheretherketone (PEEK)material is molded to the interior surface of the porous base and extends distally out of the opening at the distal end of the extension.