MULTI-LAYERED IMPLANT

1 . A multi-layered implant, comprising:

a Metal Injection Molded body comprising a titanium alloy;

a porous coating layer on a first surface of the Metal Injection Molded body; and

a zirconium alloy layer on a second surface of the Metal Injection Molded body, the first surface and the second surface being on opposite sides of the Metal Injection Molded body.

2 . The multi-layered implant of claim 1 , wherein the porous coating layer comprises a titanium-based porous coating.

3 . The multi-layered implant of claim 1 , further comprising a zirconia layer over the zirconium alloy layer.

4 . The multi-layered implant of claim 1 , wherein the zirconium alloy layer comprises a zirconium-niobium alloy.

5 . The multi-layered implant of claim 1 , wherein the multi-layered implant is a knee implant, a shoulder implant, an ankle implant, a spine implant, a disc implant, or a hip implant.

6 . A knee implant, comprising:

a titanium alloy substrate;

a porous coating layer on a first surface of the titanium alloy substrate;

a zirconium alloy layer on a second surface of the titanium alloy substrate, the first surface and the second surface being on opposite sides of the titanium alloy substrate; and

a zirconia layer over the zirconium alloy layer.

7 . The knee implant of claim 6 , wherein the porous coating layer comprises titanium-based porous coating.

8 . The knee implant of claim 6 , wherein the zirconium alloy layer comprises a zirconium-niobium alloy.

9 . A method of manufacturing a multi-layered implant, the method comprising:

providing a Metal Injection Molded body comprising a titanium alloy;

applying a porous coating on a first surface of the Metal Injection Molded body to form a porous coating layer, and a zirconium alloy on a second surface of the Metal Injection Molded body to form a zirconium alloy layer, the first surface and the second surface being on opposite sides of the Metal Injection Molded body; and

oxidizing the zirconium alloy layer to form a zirconia layer over the zirconium alloy layer.

10 . The method of claim 9 , wherein providing the Metal Injection Molded body comprises receiving the Metal Injection Molded body.

11 . The method of claim 9 , wherein providing the Metal Injection Molded body comprises molding the Metal Injection Molded body.

12 . The method of claim 9 , wherein applying the zirconium alloy on the second surface of the Metal Injection Molded body comprises over-molding the zirconium alloy on the second surface of the Metal Injection Molded body to form the zirconium alloy layer.

13 . The method of claim 9 , further comprising:

sintering the Metal Injection Molded body; and

hot isostatic pressing the Metal Injection Molded body.

14 . The method of claim 13 , wherein sintering the Metal Injection Molded body comprises:

sintering the porous coating on the first surface of the Metal Injection Molded body; and

sintering the zirconium alloy on the second surface of the Metal Injection Molded body.

15 . The method of claim 9 , further comprising polishing the zirconium alloy layer.

16 . The method of claim 15 , wherein polishing the zirconium alloy layer comprises applying an abrasive finishing process to the zirconium alloy layer.

17 . The method of claim 9 , further comprising heat treating the zirconium alloy layer.

18 . The method of claim 9 , wherein oxidizing the zirconium alloy layer comprises heating the zirconium alloy layer in an oxidative environment to form the zirconia layer.

19 . The method of claim 9 , further comprising mechanically finishing the zirconia layer.

20 . The method of claim 9 , wherein the zirconium alloy comprises a zirconium-niobium alloy.