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Medical Injection Molding

Location:
Monroe, NY, 10950
Posted:
July 22, 2016

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Resume:

Daniel E. Lawrynowicz, Ph.D.

** ******* ****, ******, ** 10950

Home: 845-***-**** Cell: 845-***-****

Email: ********@*****.***

Leadership Profile:

Driven, intelligent and highly engaging leader with a proven 26 year track record of leveraging strategic thinking, technical leadership,

business acumen, and learning agility in consistently delivering transformational results. Diverse background of experience with an unmatched ability to identify opportunity, formulate decisive plan, gain executive support and lead a team to bring products or technology to market. Passionately curious about what makes people and technology function and creates an infectious culture of achieving what others are afraid to contemplate.

Experience:

Senior Director, Advanced Technology October 2001-June 2016

Stryker Orthopaedics, Mahwah, New Jersey

Built and led a highly engaged group of 41 research engineers (23 Ph.D.’s 11Masters) and scientists developing next generation material and processing innovations as well as supporting current product manufacturing and problem solving focused on production of medical implants

Consistently achieved the highest Gallup employee engagement score within the Orthopedics Group (top 99 percentile) for Advanced Technology team for 7 consecutive years

Awarded 14 US patents with 11 more pending published applications for new materials/ processing of medical implants and related processing technology

Championed Laser and Electron Beam 3-D printing technology starting in 2004, resulting in creating a market leading position in additive manufacturing of implantable titanium devices with 5 FDA cleared components to date generating more than $130M of revenue in last 4 years and taking market share from the competition

Developed plan, orchestrated consensus and ultimately convinced the Stryker Board of Directors and CEO to invest $53M into a Center of Excellence for Additive Manufacturing which has resulted in commissioning a total of 23 production machines and 6 research machines dedicated to maintaining leading position in the market place, driving growth and enabling new designs of implants never before possible

Invented and commercialized first official “trade secret” process for surface transformation of titanium metal into hard ceramic for orthopedic bearings which has been chartered into 4 unique products projected to gross $1.2B within 5 years of launch

Conceptualized, developed and brought to production 3 generations of porous titanium foam for bone in-growth with progressive cost and quality improvements resulting in more than $900M of product sales over last 11 years

Developed in-depth understanding of design controls for NTDP, pFMEA, Fault Tree Analysis, Risk Analysis, and clinically relevant testing protocols for new materials and processing used for regulated environments and responsible for crafting majority of content for 8 successful FDA 510K submissions

Responsibly managed $14M annual budget with P/L accountability while reporting directly to the President of the Orthopedics group and delivering more than $1B of revenue generating technologies over the last 11 years

Extremely successful in building authentic relationships with peers, senior executives and direct reports resulting in building trust, consensus, and collaboration across divisions and functional groups in order to deliver uncommon results

Identified and implemented a novel process for low cost manufacturing of UHMWPE which resulted in a $11M annual savings and improved quality and yield

Played key role in performing due diligence and technology assessment for numerous M&A opportunities

Vice President (part Owner), Materials Research & Development July 1998-August 2001

Liquid Metal Composites, Inc., Corona, California

Convinced 4 career corporate leaders to invest life savings, along with my own, into funding a startup materials manufacturing company which we later sold for a profit.

Conceptualized a new low cost manufacturing method for metal matrix composites using both powder metallurgy and melt stirring technology for use in aerospace, automotive and biomedical applications

Assembled a world-class team of scientists, marketing personnel, financial experts, manufacturing partners and strategic alliances to facilitate business operations of Liquid Metal Composites, Inc.

Created more than $2.5 million of equity and assets comprising of equipment, tooling, inventory and samples through skillful negotiations and creative financing

Set up a 5,000 square foot manufacturing and laboratory/testing facility for production of metal matrix composites.

Wrote test procedures, quality plan, DOE’s and administered a full scale characterization of mechanical/physical material properties of composite materials including: tensile strength, compressive strength, fatigue, impact strength, wear resistance, corrosion resistance, abrasion resistance, expansion coefficient and thermal conductivity using internal resources and outside labs and universities

Worked with Pratt & Whitney and HDA Forgings LTD, UK on a development program for using metal matrix composites to forge large fan section engine blades

Traveled extensively to Europe and throughout the United States meeting with various customers and manufacturers with regards to material properties, performance, testing, specifications and design

Gained extensive property and specification knowledge of many classes of materials for diverse applications such as F1 automotive racing, jet engine components, electronic packaging, sporting goods, power generation and biomedical devices

Established extensive experience in capabilities and limitations of processing methods such as extrusion, forging, rolling, casting, machining, welding, cutting and drawing as they apply to various engineering materials

Scaled laboratory developed materials synthesis processes for high volume commercial production

Director, Advanced Material Production/R&D January 1996-July 1998

ALYN Corporation, Irvine, California

Responsible for the operations of research and development laboratory including materials testing, failure analysis and support of manufacturing operations for making advanced composites for Formula 1 and nuclear shielding applications

Assembled and administered budget proposals for internal and external research and development efforts

Planned and coordinated the daily activities of (7) laboratory technicians, (4) engineers and (6) production workers in support of metal matrix composites production and development

Served as technical advisor for all materials development programs with various industrial partners and potential customers

Wrote and critiqued several Small Business Innovation Research (SBIR) proposals related to processing engineering materials resulting in an award of a Phase II grant for developing a neutron attenuating metal matrix composite used in storage casks for spent nuclear fuel

Managed a full scale characterization of mechanical/physical properties of internally produced composites including: microscopy, metallography, tensile strength, compressive strength, fatigue, impact strength, wear resistance, corrosion resistance, abrasion resistance, expansion coefficient and thermal conductivity

Coordinated the effort to characterize various surface treatments and finishes for aluminum composites including: mechanical surface treatments, electrolytic and chemical polishing, chemical conversion coatings and decorative and protective anodizing

Developed proprietary process methodology for fabricating metal matrix composites on a laboratory scale and transferred and scaled the technology to enable high volume production of metal matrix composites using melt stirring and powder metallurgy

Conducted a long-term welding evaluation program for TIG, MIG, E-Beam and friction stir welding of metal matrix composites to other engineering materials

Investigated the suitability (in terms of cost vs. performance) a variety of metal forming processes for fabricating composite components (forging, extrusion, rolling, stamping, coining, swaging, drawing, lapping, EDM machining, laser and ultrasonic cutting, semi-solid casting, die casting, sand casting, permanent mold casting, squeeze casting and welding)

Participated in production planning and quality control issues (i.e., interpreted customer requirements and tried to anticipate potential problems with manufacturing methods or testing and verification of properties)

Managed cooperative research efforts with the University of California, Irvine and Case Western Reserve University, OH

Project Manager (Failure Analysis Engineer) May 1995-January 1996

LRA Laboratories, Inc., (Failure Analysis & Materials Design) Newport Beach, California

Coordinated day-to-day technical and administrative activities of failure analysis laboratory and office

Prepared quotes and budget proposals for failure analysis or testing of engineered components

Delegated various aspects of a failure investigation to any of the engineers, technicians or consultants responsible for conducting specific tests or tasks

Assembled test results, rationalized the root cause of failure, and suggested a solution based on available test data and evidence

Interfaced with clients, wrote final reports and prepared technical presentations

Evaluated creep resistance and high temperature fatigue of numerous superalloy bolts and screws used in aerospace and high temperature corrosive applications

Investigated failure mechanisms of a wide variety of components including: jet engine blades, propellers, pistons, circuit boards, industrial machinery, structural bolts, heart valves, polymer composites and many others

Served as a legal expert for titanium and stainless steel metallurgy

Developed expertise with many analytical tools such as SEM, TEM, EDAX, XPS, FTIR, XRD, DSC, DTA, ICP, image analysis, mechanical testing and physical property testing

Conducted a systematic metallurgical evaluation of the suitability of several candidate materials and coatings to be used for bio-medical devices

Served on a committee to implement a new standard (ASTM F1624) on hydrogen embrittlement testing using an accelerated test method

Helped develop a patented (Patent #836*****-****) mechanical/electronic device for measuring the stress corrosion susceptibility of metals in various corrosive environments

Developed highly specialized test equipment to simulate fatigue and wear of metallic/plastic bio-medical devices (heart valves and spinal screws)

Developed and implemented a test program for NASA to evaluate the stress corrosion susceptibility of the casing of the solid rocket boosters on the space shuttle

Managed a test program for evaluating galvanic coupling effects of dissimilar metals used in a variety of aerospace applications

Research Assistant September 1992-December 1995

University of California, Irvine, California

Designed and built a commercial sized apparatus for fabricating spray atomized composites

Developed technique to fabricate continuous fiber intermetallic matrix composites (IMCs) using spray atomization and deposition

Characterized a variety of mechanical, physical and thermal properties (including: tensile, yield, modulus, fatigue, corrosion, thermal expansion, heat of fusion, and crystal structure) of many spray formed composites

Optimized processing parameters of spray forming methods such as atomization and plasma deposition to obtain a desired grain size and microstructure

Worked with Electro Plasma (Irvine, CA) to develop co-injection and in-situ synthesis methods for fabricating various composites using low-pressure plasma deposition (LPPD)

Investigated various diagnostic techniques (including: Phase/Doppler Particle Analysis (P/DPA), Electrical Principal Base Monitoring (EPMP), Infrared Thermal imaging, used to monitor industrial spray forming processes

Presented numerous technical papers at industry sponsored conferences

Conceptualized and wrote several Small Business Innovation Research (SBIR) proposals related to processing metal matrix composite materials

Developed novel synthesis methods for fabricating composite materials with a tailored expansion coefficient and mechanical strength

Materials Engineer(COOP) December 1990-September 1991

General Electric Aircraft Engines, Lynn, Massachusetts

Evaluated new plasma deposition techniques and materials for thermal barrier coatings of hot section turbine blades

Performed failure analysis investigations of various turbine hardware including: fan blades, turbine blades, vanes, stators, shrouds, combustion liners and after burner components and recommended corrective action based on findings

Coordinated life analysis characterization of various nickel and cobalt based superalloys such as Hastelloy X, Rene 80, Waspaloy and Udimet 700 in corrosive environments

Investigated fretting failures on gas turbine disks and blades and developed a practical low cost solution to the problem

Developed non-destructive materials analysis methods for life analysis predictions using ultrasonic techniques

Performed metallography and optical and SEM characterization of various superalloy turbine engine components

Managed material selection and design analysis for select new engine hardware

Conducted welding studies of various superalloys to determine extent of heat affected zone (HAZ) and gamma prime size and distribution

Evaluated heat treatment modifications on superalloys turbine components to achieve optimum balance of strength, creep and corrosion resistance

Performed a materials property characterization investigations for directionally solidified and single crystal investment cast turbine blades.

Worked as part of a multi-disciplined task group to optimize cooling channel design for hot section engine blades

Education:

University of California, Irvine, California June 1995

Ph.D. in Materials Engineering

Dissertation: Process Modeling, Synthesis and Characterization of Spray Atomized and Deposited Ni3Al/Al2O3 Composites Used on Jet Turbine Blades

University of California, Irvine, California September 1994

Master of Science in Materials Engineering

Thesis: Microstructure and Behavior of Intermetallic Matrix Composites Processed by Spray Methods

Rensselaer Polytechnic Institute, Troy, New York May 1992

Bachelor of Science in Materials Engineering

Academic Experience:

Lecturer March 1998-June 1998

Lecturer March 1999-June 1999

University of California, Irvine, California (Department of Materials Science and Engineering)

Assembled, organized and taught course material for senior/graduate level engineering class “Failure Analysis Investigations” (class size: ~24 students)

Equipment Knowledge:

Additive manufacturing equipment for metals and plastics, optical microscope with image analysis, scanning electron microscope (SEM), transmission electron microscope (TEM), x-ray diffraction (XRD), energy dispersive x-ray (EDX), dilatometer, heat treat furnaces, cold isostatic press (CIP), hot isostatic press (HIP), vacuum sintering ovens, metallographic and polishing equipment, ultrasonic test probes, CNC lathes and mills, tensile test equipment, fracture/impact toughness test equipment, inductively coupled plasma (ICP) wet chemistry apparatus, spray atomization equipment, particle size analyzers, differential thermal analyzer (DTA), differential scanning calorimeter (DSC)

Process Knowledge:

3-D printing including laser and ebeam, forging, extrusion (metals and polymers), heat treatment, plasma spray coating, high velocity oxy-fuel (HVOF) coatings, vacuum metalizing, friction stir welding, electron beam welding, laser welding, gas-tungsten arc welding, gas-metal arc welding, conventional and EDM machining, stamping, swaging, coining, drawing, rolling, sand casting, die casting, permanent mold casting, investment casting, semi-solid casting, squeeze casting, directionally solidified investment casting, broaching, anodizing, electro plating, water jet cutting, sand/bead blasting, injection molding of PEEK, metal injection molding of Titanium

Honors:

Successfully completed Gallup Great Managers Program I and II

Successfully completed a 1 year long “mini MBA” at Harvard University

Selected for and successfully completed a year-long Stryker Advanced Development Program reserved for 25 of the highest potential individuals out of 23,000 employees

“Most Disruptive Technology Award 2004” within the Orthopedics business unit of Stryker Corporation for developing an economical process for creating 3-D interconnected porous titanium structures for bone in-growth

“Best Invention 2005” at Stryker Corporate R&D awards for nano-ceramic coating

ASM Henry Marion Howe Medal (1997) for best paper published in Metallurgical Transactions “Particle Penetration Mechanisms of a Spray Atomized and Co-Deposited Ni3Al+B/Al2O3 Metal Matrix Composite”

Alpha Sigma Mu (Materials Engineering Honorary Society) Member

General Electric Achievement Award

Professional references available upon request

Patents Issued:

METHOD OF IMPROVING BOND STRENGTH OF POLYMERIC IMPLANTS WITH BONE CEMENT

Patent number: 9193033

Abstract: A method for improving the bond between a PEEK joint component and bone cement comprising roughening a surface of the PEEK component by air-blasting abrasive water-soluble particles against the component until an average surface roughness of 4 to 6 micrometers is attained and subsequently submerging the component in water to dissolve any residual particles.

Filed: March 11, 2013

Date of Patent: November 24, 2015

Inventors: Zongtao Zhang, Keenan Michael Hanson, Daniel E. Lawrynowicz

METHOD FOR FABRICATING A BIOCOMPATIBLE MATERIAL HAVING A HIGH CARBIDE PHASE AND SUCH MATERIAL

Patent number: 8920534

Abstract: A method of fabricating a material having a high concentration of a carbide constituent. The method may comprise adding a carbide source to a biocompatible material in which a weight of the carbide source is at least approximately 10% of the total weight, heating the carbide source and the biocompatible material to a predetermined temperature to melt the biocompatible material and allow the carbide source to go into solution to form a molten homogeneous solution, and impinging the molten homogeneous solution with a high pressure fluid to form spray atomized powder having carbide particles. The size of a particle of carbide in the atomized powder may be approximately 900 nanometers or less. The biocompatible material may be cobalt chrome, the carbide source may be graphite, and the fluid may be a gas or a liquid.

Filed: March 26, 2007

Date of Patent: December 30, 2014

Inventors: Daniel E. Lawrynowicz, Aiguo Wang, Zongtao Zhang, Haitong Zeng

METHODS FOR MANUFACTURING POROUS ORTHOPAEDIC IMPLANTS

Patent number: 8727203

Abstract: A method of manufacturing an orthopedic implant device having a porous outer surface is described. In one embodiment, the implant device includes a porous layer, an intermediate layer, and a solid substrate. The porous layer is preferably bonded to the intermediate layer by cold isostatic pressing. The intermediate layer is preferably bonded by vacuum welding to the solid substrate such that the porous layer forms at least a portion of the outer surface of the orthopedic implant device. Preferably, a diffusion bond is created between the bonded intermediate layer and the solid substrate by hot isostatic pressing. In another embodiment, a porous layer is created on an outer surface of a solid layer by selective melting. Preferably, the solid layer is bonded to the solid substrate such that the porous layer forms at least a portion of the outer surface of the orthopedic implant device.

Filed: September 16, 2010

Date of Patent: May 20, 2014

Inventors: Aiguo Wang, Daniel E. Lawrynowicz, Haitong Zeng, Naomi Murray, Balaji Prabhu

POLYETHYLENE CROSS-LINKED WITH AN ANTHOCYANIN

Patent number: 8439975

Abstract: A method for manufacturing of ultrahigh molecular weight polyethylene (UHMWPE) for implants, where the implants have been machined out of UHMWPE blocks or extruded rods, has anthocyanin dispersely imbedded in the polyethylene. The implant is then exposed to ? ray or electron beam irradiation in an amount of at least 2.5 Mrad followed by a heat treatment to prevent the implant from becoming brittle in the long term as well as to improve strength and wear. The method includes mixing a powder or granulate resin of UHMWPE with an aqueous liquid that contains anthocyanin in a predetermined amount. The water is then evaporated to deposit the anthocyanin in a predetermined concentration on the polyethylene particles. The doped UHMWPE particles are compressed into blocks at temperatures in a range of approximately 135 C.-250 C. and pressures in a range of approximately 2-70 MPa. Medical implants are made from the blocks.

Filed: September 20, 2012

Date of Patent: May 14, 2013

Inventors: Shulin He, Shi-Shen Yau, Aiguo Wang, Daniel E. Lawrynowicz

LASER-PRODUCED IMPLANTS

Patent number: 8350186

Abstract: A method of producing an orthopedic implant including the steps of building a flat open model of at least a portion of an implant. The flat open model may be built using a selective laser sinter process. The flat open model preferably includes at least one groove along either a first surface or a second surface of the model. Next a force may be applied to the flat open model at predetermined locations to thereby cause the model to bend and assume a shape similar to a desired result. The now bent model may be resurfaced by either applying additional material such that the bent flat open model assumes the shape of a desired implant or the bent open model may be snap fit to an additional element.

Filed: December 29, 2006

Date of Patent: January 8, 2013

Inventors: Eric Jones, Christopher J. Sutcliffe, Aiguo Wang, Daniel E. Lawrynowicz

POLYETHYLENE CROSS-LINKED WITH AN ANTHOCYANIN

Patent number: 8303657

Abstract: A method for manufacturing of ultrahigh molecular weight polyethylene (UHMWPE) for implants, where the implants have been machined out of UHMWPE blocks or extruded rods, has anthocyanin dispersely imbedded in the polyethylene. The implant is then exposed to x- ray or electron beam irradiation in an amount of at least 2.5 Mrad followed by a heat treatment to prevent the implant from becoming brittle in the long term as well as to improve strength and wear. The method includes mixing a powder or granulate resin of UHMWPE with an aqueous liquid that contains anthocyanin in a predetermined amount. The water is then evaporated in order to deposit the anthocyanin in a predetermined concentration on the polyethylene particles. The doped UHMWPE particles are compressed into blocks at temperatures in a range of approximately 135 C.-250 C. and pressures in a range of approximately 2-70 MPa. Medical implants are made from the blocks.

Filed: May 25, 2011

Date of Patent: November 6, 2012

Inventors: Shulin He, Shi-Shen Yau, Aiguo Wang, Daniel E. Lawrynowicz

POLYETHYLENE CROSS-LINKED WITH AN ANTHOCYANIN

Patent number: 8241564

Abstract: A method for manufacturing of ultrahigh molecular weight polyethylene (UHMWPE) for implants, where the implants have been machined out of UHMWPE blocks or extruded rods, has anthocyanin dispersely imbedded in the polyethylene. The implant is then exposed to x- ray or electron beam irradiation in an amount of at least 2.5 Mrad followed by a heat treatment to prevent the implant from becoming brittle in the long term as well as to improve strength and wear. The method includes mixing a powder or granulate resin of UHMWPE with an aqueous liquid that contains anthocyanin in a predetermined amount. The water is evaporated in order to deposit the anthocyanin in a predetermined concentration on the polyethylene particles. The doped UHMWPE particles are compressed into blocks at temperatures in a range of approximately 135 C.-250 C. and pressures in a range of approximately 2-70 MPa. Medical implants are made from the blocks.

Filed: February 17, 2012

Date of Patent: August 14, 2012

Inventors: Shulin He, Shi-Shen Yau, Aiguo Wang, Daniel E. Lawrynowicz

METHOD FOR FABRICATING A MEDICAL IMPLANT COMPONENT AND SUCH COMPONENT

Patent number: 8187660

Abstract: A method of fabricating a medical implant component. The method may include the steps of producing a substrate from a first material wherein the substrate has a bearing portion, spraying particles of a second material onto the bearing portion in accordance with a predetermined spraying technique to provide a coating thereon, and subjecting the coated bearing portion to a hot isostatic pressing process, a vacuum sintering process, or a controlled atmospheric sintering process. The first material may be the same as or different from the second material. The predetermined spraying technique may be a thermal type spraying process such as a plasma spraying process or a high velocity oxygen fuel spraying process.

Filed: January 5, 2006

Date of Patent: May 29, 2012

Inventors: Daniel E. Lawrynowicz, Aiguo Wang

POLYETHYLENE CROSS-LINKED WITH AN ANTHOCYANIN

Patent number: 8133436

Abstract: A method for manufacturing of ultrahigh molecular weight polyethylene (UHMWPE) for implants, where the implants have been machined out of UHMWPE blocks or extruded rods, has anthocyanin dispersely imbedded in the polyethylene. The implant is then exposed to x- ray or electron beam irradiation in an amount of at least 2.5 Mrad followed by a heat treatment to prevent the implant from becoming brittle in the long term as well as to improve strength and wear. The method includes mixing a powder or granulate resin of UHMWPE with an aqueous liquid that contains anthocyanin in a predetermined amount. The water is then evaporated in order to deposit the anthocyanin in a predetermined concentration on the polyethylene particles. The doped UHMWPE particles are compressed into blocks at temperatures in a range of approximately 135 C.-250 C. and pressures in a range of approximately 2-70 MPa. Medical implants are made from the blocks.

Filed: August 5, 2008

Date of Patent: March 13, 2012

Inventors: Shulin He, Shi-Shen Yau, Aiguo Wang, Daniel E. Lawrynowicz

METHOD FOR FABRICATING A MEDICAL COMPONENT FROM A MATERIAL HAVING A HIGH CARBIDE PHASE AND SUCH MEDICAL COMPONENT

Patent number: 8057914

Abstract: A method of fabricating a medical implant component. The method may comprise producing a substrate from a first material in which the substrate has a bearing portion, and causing particles of a second material to be formed onto at least the bearing portion of the substrate. The second material may be formed from a biocompatible material and a carbide source, in which the carbide source is 6.17% or more of the second material by weight. The particles of the second material may be formed onto at least the bearing portion of the substrate by a predetermined spraying technique, a CVD process, a PVD process, or a carburization process. The biocompatible material may be cobalt chrome and the carbide source may be graphite.

Filed: March 26, 2007

Date of Patent: November 15, 2011

Inventors: Daniel E. Lawrynowicz, Aiguo Wang, Zongtao Zhang

MULTI-STATION ROTATION SYSTEM FOR USE IN SPRAY OPERATIONS

Patent number: 7981479

Abstract: A system and method for use in applying a coating of a desired material onto one or more medical implant components. The system may include one or more thermal sprayers and a rotatable holding fixture having a plurality of mounting stations each operable to hold at least one medical implant component. The fixture may be operable to rotate about a central axis and each mounting station may be operable to rotate about a respective mounting station axis. The fixture may be arranged adjacent to one or more thermal sprayers so that during operation one or more desired materials may be sprayed by the one or more thermal sprayers upon an outer surface of each of the medical implant components while the fixture rotates about the central axis and while simultaneously therewith each of mounting stations having a respective medical implant component rotates about the respective mounting station axis.

Filed: February 17, 2006

Date of Patent: July 19, 2011

Inventors: Daniel E. Lawrynowicz, Aiguo Wang, Zongtao Zhang, Jay Krajewski

MULTI-STATION ROTATION SYSTEM FOR USE IN SPRAY OPERATIONS

Patent number: 7836847

Abstract: A system and method for use in applying a coating of a desired material onto one or more medical implant components. The system may include a thermal sprayer and a rotatable holding fixture having a plurality of mounting stations each operable to hold at least one medical implant component. The fixture may be operable to rotate about a central axis and each mounting station may be operable to rotate about a respective mounting station axis. The fixture may be arranged adjacent to the thermal sprayer so that during operation the desired material may be sprayed by the thermal sprayer upon an outer surface of each of the medical implant components while the fixture rotates about the central axis and while simultaneously therewith each of mounting stations having a respective medical implant component rotates about the respective mounting station axis

Filed: February 17, 2006

Date of Patent: November 23, 2010

Inventors: Daniel E. Lawrynowicz, Aiguo Wang, Zongtao Zhang, Jay Krajewski

METHOD FOR FABRICATING A MEDICAL COMPONENT FROM A MATERIAL HAVING A HIGH CARBIDE PHASE

Patent number: 7771775

Abstract: A method of fabricating a medical implant component. The method may comprise producing a substrate from a first material in which the substrate has a bearing portion, and spraying particles of a second



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