Patent ID: 7968037

Claim:
A method of manufacturing an elongated spinal fixation member comprising: providing a medical-grade polymer; providing a mold for creating an elongated spinal fixation member, the mold including a main cavity shaped to form an arcuate main body of the spinal fixation member having: a first end portion, a second end portion, and an elongated central portion extending substantially between the first end portion and the second end portion, the arcuate main body curved along its length between the first end portion and the second end portion; the central portion having a substantially uniform oblong cross-section extending substantially along a length of the central portion, the cross-section having a height greater than a width as viewed in a plane generally perpendicular to the length of the central portion, the first end portion having a substantially circular first end-portion surface and a first end-cap opening extending therethrough, the first end portion having at least one external taper transitioning the first end portion from the oblong cross-section of the central portion to the substantially circular first end-portion surface, the at least one external taper of the first end portion tapering more relative to the height of the central portion as compared to the width of the central portion; heating the polymer to a temperature between 600° and 800° Fahrenheit; injecting the polymer into the main cavity of the mold at a temperature between 300° and 500° Fahrenheit and a pack pressure between 5,000 and 15,000 PSI until the main cavity is completely filled with the polymer with a peak pressure between 15,000 and 25,000 PSI; holding the injected polymer in the mold at a hold pressure between 15,000 and 25,000 PSI; and removing the polymer from the mold.