Orthopaedic implants (110) exhibiting improved fatigue strength are disclosed. By forming a plurality of nodules (100) on the surface of an implant and depositing a porous coating (114) onto the surface of these nodules, the fatigue strength of implants such as those made from α + β titanium alloys, e.g., Ti-6A1-4V alloy is substantially improved. The present invention provides a novel geometry which substantially reduces the stress concentration factor created by the interfacial geometry of conventional porous coatings. Methods of manufacturing porous coated orthopaedic implants (110) are also disclosed.