System and method of manufacture for spinal implant

A method for fabricating a bone screw, the method comprising the steps of:

• disposing a build plate within a working chamber of an additive manufacturing apparatus, the plate including at least one cavity;
• orienting the insert within the at least one cavity such that the at least one cavity orients the insert for forming at least a portion of a screw shaft thereon using the additive manufacturing apparatus based on selected configuration parameters;
• and
• forming the at least a portion of the screw shaft by adding material in a layer by layer manner.

An additive manufacturing apparatus comprising:

• an enclosure defining a working chamber;
• a laser device;
• and
• a build plate disposed in the working chamber, the plate defining at least one cavity, and
• an insert sized and shaped to fit within the at least one cavity such that the at least one cavity orients the insert for forming at least a portion of a screw shaft thereon by selective laser melting of a material onto the insert to form the at least a portion of a screw shaft with a powder bed process.