Method of constructing prosthetic implant with wrapped porous surface

A method of constructing a prosthetic implant comprising the following steps:

• (a) providing a base metal implant including a stem portion having a medial, a posterior, an anterior, and a lateral side;
• (b) forming a sheet of porous fiber metal material;
• (c) prebonding the sheet to bond the fiber metal material together;
• (d) cutting a porous pad from the sheet to provide the pad with an outer boundary defining a desired contour and having a substantially flat first configuration;
• (e) wrapping the pad around the stem portion for attachment thereto in a second non-flat configuration conforming to the shape of the stem portion about which the pad is wrapped;
• and
• (f) applying to said pad, thereby converting said a plurality of sequentially applied forming jaws substantially flat first configuration to the non-flat second configuration, said plurality of jaws applying such force to the pad in a desired sequence, with one of said plurality of jaws initially contacting with and applying force to the pad first, and with at least one other of the plurality of jaws subsequently contacting with and applying force to the pad thereafter.

A method of constructing a prosthetic implant comprising the following steps:

• (a) providing a base implant including a stem portion having a plurality of sides;
• (b) providing a separate porous pad having a first desired configuration which is substantially flat;
• (c) wrapping the pad around the stem portion for attachment thereto in a second non-flat configuration conforming to the shape of the stem portion about which the pad is wrapped;
• (d) providing a fixture having a first forming jaw, and second and third forming jaws oppositely located from each other and each adjacent the first jaw, and a fourth forming jaw adjacent the second and third jaws and oppositely located from the first jaw;
• and
• (e) sequentially applying the forming jaws to said pad, thereby converting said substantially flat configuration to the non-flat second configuration, whereby said applying mechanical force step comprises initially advancing the first jaw to the pad and holding the pad against one of the sides of the stem portion, then subsequently advancing both of the second and third jaws simultaneously to the pad and holding the pad against two other sides of the stem portion, and then finally advancing the fourth jaw pressing the pad against another side of the stem portion, thereby conforming the pad to the stem portion.

A method of constructing a prosthetic implant comprising the following steps:

• (a) providing a base portion including a stem portion having a plurality of sides;
• (b) providing a separate porous pad having a first desired configuration which is substantially flat;
• (c) providing a separate forming die and initially forming a first side of the pad with said die to convert the first substantially flat configuration to a substantially U-shaped configuration;
• (d) providing a forming fixture having a first jaw, and second and third jaws oppositely located from each other and each adjacent the first jaw, and a fourth jaw adjacent the second and third jaws and oppositely located from the first jaw, and wherein the jaws are all initially in a retracted position;
• (e) positioning the pad having the substantially U-shaped configuration between the base portion and the retracted jaws and then initially advancing the first jaw to the first side of the U-shaped pad to hold the pad against one of the sides of the stem portion, then subsequently advancing both of the second and third jaws simultaneously to the pad and holding the pad against two other sides of the stem portion, and then finally advancing the fourth jaw pressing the pad against another side of the stem portion, thereby conforming the pad to the stem portion.

A method of constructing a prosthetic implant comprising the following steps:

• (a) providing a base portion including a stem portion having a plurality of sides;
• (b) precontouring a separate porous pad having a first desired configuration which is substantially flat;
• (c) wrapping the pad around the stem portion for attachment thereto in a second non-flat configuration conforming to the shape of the stem portion about which the pad is wrapped;
• and
• (d) applying a plurality of sequentially applied forming jaws to said pad, thereby converting said substantially flat first configuration to the non-flat second configuration, said plurality of jaws applying such force to the pad in a desired sequence, with one of said plurality of jaws initially contacting with and applying force to the pad first, and with at least one other of the plurality of jaws subsequently contacting with and applying force to the pad thereafter.

A method of constructing a prosthetic implant comprising the following steps:

• (a) providing a base portion including a stem portion having a plurality of sides;
• (b) providing a separate porous pad having a first desired configuration which is substantially flat;
• (c) providing a separate forming die and initially forming a first side of the pad with said die, thereby converting said pad from the first substantially flat configuration to a substantially U-shaped configuration;
• (d) providing a forming fixture having a plurality of sequentially applied forming jaws and wherein the jaws are all initially in a retracted position;
• (e) positioning the pad having the substantially U-shaped configuration between the base portion and the retracted jaws and then initially advancing one of said plurality of jaws to the first side of the U-shaped pad, thereby holding the pad against one of the sides of the stem portion first, and then subsequently advancing at least one other of the plurality of jaws, thereby contacting with and applying force to the pad thereafter, thereby conforming the pad to the stem portion.