An improved method for manufacturing prosthetic bones is examined. We are developing a new improved method for designing and manufacturing prosthetic bones that have a porous interior core covered by a solid outer shell, more closely matching the morphology of natural bone. The new method is compatible with a wide variety of materials, including polymers, metals, composites, and biodegradable scaffold materials. Use of biodegradable scaffold material holds the potential for eventual bone regeneration within and throughout the prosthesis. Regardless of the material selection, this improved type of prosthesis is expected to more closely mimic the overall material and structural properties of natural bone, including shape, strength, weight, and weight distribution. By fabricating prosthetic bones that duplicate the material and structural properties of natural bone, implants could be made to operate as precision replacements, feeling and functioning exactly like natural bone. In addition to improving patient comfort, these new prostheses are expected to reduce the occurrence of unnatural secondary wear patterns caused by current style prosthetic bones that function in unnatural fashions due to their non-matching material and structural properties.

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