Custom bioimplantable article

A method of making a custom joint prosthesis component comprising the steps of:

• creating a data file with a computer aided design program that defines a three-dimensional shape of at least a portion of the custom joint prosthesis component;
• providing a rapid prototyping apparatus;
• providing the data file to the rapid prototyping machine;
• fabricating a mold for at least a portion of the custom joint prosthesis component with the rapid prototyping machine by forming a ceramic shell as defined by the data file;
• providing a plurality of non-custom representations of a biomedical article;
• selecting one of the non-custom representations of the biomedical article;
• juxtaposing the selected, non-custom representation of a biomedical article with the mold;
• attaching the selected, non-custom representation of a biomedical article to the mold with refractory cement to define a hybrid component;
• creating a ceramic shell around the hybrid component;
• removing the selected, non-custom representation of a biomedical article from the ceramic shell by heating the selected, non-custom representation of a biomedical article to a molten state;
• and
• allowing the molten article to flow out of the ceramic shell;
• introducing molten metal into the ceramic shell;
• allowing the molten metal to harden;
• and
• removing the ceramic shell from the hardened metal.

A method of making a custom orthopedic implant comprising the steps of:

• creating a custom orthopedic implant model using computer aided design techniques;
• creating a shell of the orthopedic implant model using computer aided design techniques;
• forming a ceramic mold representative of the shell of the orthopedic implant model with a rapid prototyping machine;
• providing a heat destructible implant model;
• juxtaposing the heat destructible implant model with the ceramic mold to provide a hybrid component;
• creating a ceramic shell around the hybrid component;
• applying heat to the ceramic shell to destroy the heat destructible implant model;
• introducing molten metal into the ceramic shell;
• allowing the molten metal to harden;
• and
• removing the ceramic shell from the hardened metal.