Manufacturing and material processing for prosthetic devices

A method of manufacturing a prosthetic device, the method comprising:

• injecting a polycarbonate polyurethane into a mold to form a core, the mold comprising a mirror polished upper molding surface for defining an upper surface of the core, a mirror polished lower molding surface for defining a lower surface of the core, and one or more removable inserts for defining a plurality of recesses of the core;
• removing the one or more removable inserts;
• winding ultra high molecular weight polyethylene reinforcing fiber around the core and into at least one of the plurality of recesses of the core;
• heating the core;
• injecting a polycarbonate polyurethane into the mold to form an outer layer surrounding the core and the reinforcing fiber;
• and
• cooling the mold.

A method of forming a meniscus implant, comprising:

• injecting a polymer into a mold to form a core, the mold comprising a mirror polished upper molding surface for defining an upper surface of the core, a mirror polished lower molding surface for defining a lower surface of the core, and one or more removable inserts for defining a plurality of recesses around a perimeter of the core;
• removing the one or more removable inserts;
• winding reinforcing fiber around the core and into the plurality of recesses of the core, the reinforcing fiber tensioned with a force between about 5 N and about 78 N during the winding;
• and
• injecting a polymer into the mold to form an outer layer surrounding the core and the reinforcing fiber.