Hip implant with porous body

1. A method, comprising:

machining a neck body of a hip implant from solid metal to include a neck portion with a cylindrical configuration that receives a femoral ball at a proximal end of the neck body, a flat end surface at a distal end of the neck body, and a male protrusion that extends away from the flat end surface at the distal end of the neck body such that the male protrusion has an elongated shape that tapers while extending from the flat end surface at the distal end of the neck body to a distal end of the male protrusion and such that the male protrusion includes a non-circular shape in a cross-sectional view;

heating a biocompatible material in a furnace that fabricates a bone fixation body formed of a porous metal structure that has a tapering body that extends in a side view from a flat end surface at a proximal end of the bone fixation body to a distal end of the bone fixation body, has an external bow on one side in the side view, has a trapezoidal shape in a cross-sectional view, and has the porous metal structure that extends throughout the bone fixation body such that the porous metal structure includes a geometric configuration with a size and a shape of cancellous human bone; and

heating the bone fixation body and the neck body so that the bone fixation body permanently bonds around the neck body to form the hip implant such that the male protrusion extends into and forms a solid metal core for the bone fixation body, the flat end surface at the proximal end of the bone fixation body bonds at a junction to the flat end surface at the distal end of the neck body, and the bone fixation body and the neck body bond to provide anti-rotation at an interface where the bone fixation body bonds to the non-circular shape of the male protrusion.

2. The method of claim 1 , wherein the bone fixation body simultaneously bonds to the neck body during fabrication of the bone fixation body.

3. The method of claim 1 , wherein the bone fixation body bonds to the neck body after the bone fixation body is separately fabricated from the neck body.

4. The method of claim 1 further comprising:

fabricating the porous metal structure such that a depth of bone growth is not restricted to a thin porous coating but bone grows and integrates into the porous metal structure.

5. The method of claim 1 , wherein a porosity of the porous metal structure includes a portion with a porosity of 65%.

6. The method of claim 1 , wherein the bone fixation body is fabricated so the bone fixation body does not include a solid metal substrate.

7. The method of claim 1 , wherein an average pore diameter of the porous metal structure is 40 μm to 800 μm.

8. The method of claim 1 , wherein the bone fixation body is heated in the furnace and formed to have a shape and a contour of a human intramedullary canal in order to fit into the human intramedullary canal and conform to anatomical contours of a human patient.

9. A method, comprising:

machining solid metal to form a neck body of a hip implant that includes a neck portion at a proximal end of the neck body with a cylindrical configuration that receives a femoral ball and that includes a flat end surface at a distal end of the neck body such that a male protrusion extends outwardly from the flat end surface at the distal end of the neck body and the male protrusion tapers while extending from the flat end surface at the distal end of the neck body to a distal end of the male protrusion and includes a non-circle shape in a cross-sectional view;

heating a biocompatible material in a furnace that forms a porous metal structure that is a bone fixation body of the hip implant such that the porous metal structure formed in the furnace: includes a trapezoidal shape in a cross-sectional view, extends from a flat end surface at a proximal end of the bone fixation body to a distal end of the bone fixation body, has a tapering body that tapers from the flat end surface at the proximal end of the bone fixation body to the distal end of the bone fixation body, has an external bow on one side as seen in a side view of the hip implant, and is formed of porous metal that extends throughout the bone fixation body with the porous metal having a geometric configuration with a size and a shape of cancellous human bone such that the porous metal encourages the cancellous human bone to migrate and grow into the bone fixation body; and

heating the bone fixation body and the neck body to bond the bone fixation body around the neck body to form the hip implant such that the bone fixation body bonds to the neck body along an interface that includes a junction where the flat end surface at the proximal end of the bone fixation body bonds to the flat end surface at the distal end of the neck body and includes a portion of the male protrusion that tapers and includes the non-circular shape of the male protrusion that extends into the bone fixation body and forms a solid metal core for the bone fixation body.

10. The method of claim 9 , wherein the bone fixation body simultaneously forms and attaches to the neck body.

11. The method of claim 9 , wherein the bone fixation body and the neck body are fabricated independently and subsequently bonded together.

12. The method of claim 9 , wherein the porous metal structured is formed in the furnace to have a shape of a human intramedullary canal in order to fit into the human intramedullary canal and conform to anatomical contours of a human patient.

13. The method of claim 9 , wherein the porous metal structure includes an average pore diameter between 40 μm to 800 μm and includes a porosity with a value of 65%.

14. A method, comprising:

machining solid metal to form a neck body of a hip implant to have a proximal end with a neck portion with a cylindrical configuration that receives a femoral ball, to have a distal end with a flat end surface, and to have a male protrusion that extends outwardly from the flat end surface at the distal end of the neck body and that tapers while extending from the flat end surface at the distal end of the neck body to a distal end of the male protrusion and that includes a non-circular shape in a cross-sectional view;

heating a biocompatible material in a furnace to fabricate a porous metal structure that is a bone fixation body of the hip implant so that the porous metal structure is formed in the furnace to: extend from a flat end surface at a proximal end of the bone fixation body to a distal end of the bone fixation body, include a trapezoidal shape in a cross-sectional view, include a tapering body that tapers from the flat end surface at the proximal end of the bone fixation body to the distal end of the bone fixation body, include an external bow on one side as seen in a side view of the hip implant, be formed without a solid metal substrate, and be formed of porous metal that extends throughout the bone fixation body and that has a geometric configuration with a size and a shape of cancellous natural human bone in order to encourage bone to migrate and grow into the porous metal structure that is the bone fixation body; and

heating the bone fixation body and the neck body so the bone fixation body bonds around the neck body to form the hip implant such that the male protrusion forms a solid metal core for the bone fixation body, the flat end surface at the proximal end of the bone fixation body bonds at a junction to the flat end surface at the distal end of the neck body, and the neck body and the bone fixation body bond along an anti-rotation interface that includes where the non-circular shape of the male protrusion bonds to the bone fixation body.

15. The method of claim 14 , wherein the bone fixation body simultaneously forms and attaches to the neck body.

16. The method of claim 14 , wherein the bone fixation body and the neck body are fabricated independently and subsequently bonded together.

17. The method of claim 14 , wherein the porous metal structure forms in the furnace to have a shape of a human intramedullary canal in order to fit into the human intramedullary canal and conform to anatomical contours of a human patient.