Preformed support device and method and apparatus for manufacturing the same

1. A method of making a seamless, anatomically contoured, implantable prosthetic device for implantation within a human patient to support or maintain the position of tissue, an organ or structure or a replacement therefor, which comprises the steps of:

pre-heating an apparatus for forming the prosthetic device, the apparatus including a support plate made from a thermally conductive material and having a first opening formed through the thickness thereof and a lower surface substantially free from contact with any other surface, the first opening having a predetermined shape, an ironing plate made from a thermally conductive material and having a second opening formed through the thickness thereof, the second opening having a predetermined shape which is as least one of the same as and similar to the predetermined shape of the first opening formed in the support plate, and a core plate made from a thermally conductive material and having a lower surface and a core extending outwardly from the lower surface thereof, the core having a predetermined male form, the core being at least partially receivable by and extending through the second opening of the ironing plate and the first opening of the support plate, wherein the apparatus does not use or otherwise incorporate a female mold cavity;

placing an implantable, biocompatible mesh material on top of the support plate;

placing the ironing plate onto the mesh material so that the mesh material is sandwiched between the support plate and the ironing plate;

shrinking the mesh material between the heated support plate and ironing plate;

following the shrinking step, placing the core plate on top of the ironing plate so that the core penetrates through the ironing plate and the support plate and deforms a portion of the mesh material into a contoured shaped portion which is surrounded by excess mesh material, wherein the lower surface of the core plate and associated contoured shaped mesh portion is openly exposed;

removing the mesh material containing the contoured shaped portion from between the support plate and the ironing plate; and

separating the shaped portion from the excess mesh material, the separated shaped portion defining the seamless, anatomically contoured, prosthetic device.

2. A method as defined by claim 1 , wherein the step of pre-heating the apparatus includes the step of pre-heating the apparatus to a temperature of between about one hundred degrees Celsius and about two hundred degrees Celsius.

3. A method as defined by claim 1 , wherein after the step of placing the core plate on top of the ironing plate so that the core penetrates through the ironing plate and the support plate and deforms a portion of the mesh material into a contoured shaped portion, the method further comprises the step of maintaining the temperature of the apparatus for a predetermined period of time.

4. A method as defined by claim 3 , wherein the step of maintaining the temperature of the apparatus for a predetermined period of time includes the step of maintaining the temperature of the apparatus for a predetermined period of time from about three minutes to about three hours.

5. A method as defined by claim 3 , wherein after the step of maintaining the temperature of the apparatus for a predetermined period of time, the method further comprises the step of allowing the apparatus to cool for a predetermined period of time.

6. A method as defined by claim 5 , wherein the step of allowing the apparatus to cool for a predetermined period of time includes the step of allowing the apparatus to cool for a predetermined period of time of between about three minutes and about five hours.