Patent ID: 8038920

Claim:
A method of fabricating an implantable prosthesis, comprising: placing an inferior mesh layer on a floor of a three-dimensional mold having a mold cavity and a releasably attachable lid; introducing moldable material into the mold onto the inferior mesh layer, wherein the moldable material includes PVA crystals, granules or powder and a liquid, and wherein the introducing step is carried out by introducing the PVA material independently of the liquid; placing a superior mesh layer on a top surface of the moldable material in the mold; then closing the mold by inserting elongate attachment members with heads through springs, then into the lid so that the mold cavity can vary in volume during thermal processing while inhibiting the introduction of air into the mold cavity; and heating the mold with the moldable material to a desired temperature so that the mold is heated to at least about 80° C. for at least about 5 minutes; then forming a molded solid PVA hydrogel implant body formed by the heated moldable material whereby the mesh layers are integrally attached to the molded body.