A composite article is disclosed including a porous structural member formed of carbon fiber, the porous structural member containing a multiplicity of pores of dimensions greater than about 200 microns in diameter, the porous structural member further including carbon fill material within a portion of the pores such that the pores are essentially less than about 200 microns in diameter, the porous structural member including carbon fill material defining a composite carbon/carbon intermediate article including an outer surface and a thin coating of diamond-like carbon upon the outer surface of the composite carbon/carbon intermediate article. The composite article may serve as a prosthetic device for replacement joints, bone structures and the like.