Methods for producing medical implants with roughened, particulate-free surfaces

A method of producing a medical implant with a roughened outer surface suitable for the attachment of tissue, bone, cells, or bone cement, the method comprising the steps of:

• (a) blasting at least a portion of an outer surface of an implant with a blasting medium comprising a biocompatible liquid and biocompatible solid particulates selected from the group consisting of soluble biocompatible salts, deliquescable biocompatible solids, sublimatible biocompatible solids, and vaporizable biocompatible solids at a pressure sufficient to produce a roughened outer surface on said implant having a roughness profile and a sufficient average surface roughness capable of facilitating the attachment of tissue, bone, cells or bone cement to said outer surface of said implant;
• (b) said roughness profile including peaks and valleys about a mean line on the outer surface of said implant, the outer surface of said implant having an average surface roughness of from about 150 micro-inches to about 300 micro-inches;
• and
• (c) removing substantially all embedded and attached particulate debris left by the blasting medium when blasting said implant in order to provide a roughened outer surface substantially free of embedded and attached particulate debris from the blasting medium wherein said roughened outer surface promotes adhesion of said tissue, bone, cells, or bone cement, introduces residual compression stresses and improves fatigue strength of said medical implant.