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Additive Manufacturing of Functionally Graded Ceramic Materials by Stereolithography
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Fast plasma sintering delivers functional graded materials components with macroporous structures and
R F Godoy1, M J Coathup, G W Blunn
1Institute of Orthopaedics and Musculoskeletal Science, Brockley Hill, HA7 4LP, Middlesex, UK.r.godoy@ucl.ac.uk.
European Cells & Materials
|April 14, 2016
Summary
Fast plasma sintering (FPS) macroporous titanium surfaces demonstrate comparable osseointegration to clinical standards. These novel FPS surfaces, including TiMac400 and TiMac850, show deep bone ingrowth and potential for innovative implant design.
Area of Science:
- Biomaterials Engineering
- Orthopaedic Implant Technology
- Surface Science
Background:
- Macroporous titanium surfaces are crucial for enhancing osseointegration in orthopaedic implants.
- Current clinical surfaces include Ti-Growth® and air plasma spray (APS) coatings.
- Fast plasma sintering (FPS) is an emerging technology for creating advanced porous implant structures.
Purpose of the Study:
- To evaluate the osseointegration potential of novel macroporous titanium surfaces fabricated using FPS.
- To compare FPS-derived surfaces (TiMac400, TiMac850) against established clinical surfaces (Ti-Growth®, Ti-Y367).
- To assess the influence of substrate material (Ti-alloy, CoCr) on osseointegration.
Main Methods:
- Fabrication of macroporous titanium surfaces using FPS with defined pore sizes (400-600 µm and 850-1000 µm).
- Implantation of surfaces onto Ti-alloy and CoCr substrates into ovine femoral condyles.
- Explantation at 4 and 8 weeks for mechanical push-out testing, histomorphometry, SEM, and EDX analysis.
Main Results:
- All tested surfaces exhibited early osseointegration.
- At 8 weeks, TiMac400, TiMac850, and Ti-Growth® showed deep bone ingrowth and new bone formation.
- Mechanical push-out forces were comparable across all surfaces; FPS surfaces exhibited deeper bone integration despite larger void areas.
Conclusions:
- FPS technology effectively produces macroporous titanium surfaces with significant osseointegration potential, comparable to current clinical standards.
- FPS allows for the development of innovative implant designs by combining different materials, such as CoCr substrates with macroporous titanium.
- FPS-manufactured porous surfaces are optimized for osseointegration and represent a viable technology for orthopaedic implants.
