Patent ID: 7655162

Claim:
A method for forming an acetabular cup for use in replacing a portion of a patient's hip, the method comprising: providing a working surface onto which an acetabular cup is to be formed; spraying a first layer of material having a first composition onto the working surface, the first layer of material forming a concave inner bearing engaging surface of the acetabular cup; continuing the spraying of the first material while introducing a second material having a second composition into the spray such that a concentration of the first and second materials are sprayed together to form a mixture of the first and second materials as a second layer of material subsequent to spraying the first layer of material; continuing the spraying while reducing an amount of the first material in the concentration, such that a third layer of material consisting solely of the second material is formed, the third layer of material having an outermost surface forming a convex outer bone engaging surface of the acetabular cup capable of engaging the portion of the patient's hip, the first, second and third layers of material collectively forming the acetabular cup; and removing the acetabular cup from the working surface.