Alternative methods for custom implant production utilizing a combination of rapid prototyping technology and conventional investment casting

Conventional lost wax investment casting and rapid prototyping were combined to provide a custom orthopaedic implant that was manufactured quickly, by reducing the time required for a skilled craftsperson to perform complex wax modifications. The custom sections of the implant were produced by a rapid prototyping machine and then attached to a standard investment casting wax implant pattern to create a custom hybrid pattern for casting. This was shown to be a practical method of creating a custom implant that has acceptable surface finish and dimensional accuracy in critical areas, within a much shorter time frame than would be possible with complex custom wax pattern modifications.