Titanium mesh-reinforced calcium sulfate for structural bone grafts

Calcium sulfate (CS) possesses many of the requirements for an ideal bone graft material: it is biodegradable, biocompatible, and osteoconductive. However, its relatively low strength and brittleness are major obstacles to its use as a structural bone implant. Although the strength of CS can be improved by reducing porosity, its brittleness remains a major obstacle towards its use as bone graft. Here we combine two powerful toughening strategies which are found in advanced ceramics and in natural bone: Multi-layered architectures and ductile reinforcements. We first used stress analysis and micromechanics to generate design guidelines that ensure the proper failure sequence and maximize properties. We then fabricated and tested fully dense CS by hydrostatic compression layered with layers of titanium woven mesh. Flexural experiments in hydrated conditions confirmed that the ductility and strength of titanium and the adhesion at the titanium-CS interfaces (controlled by the size of the Ti mesh) are critical factors in the mechanical performance of the composite. Our best design exhibited a toughness 180 times larger than that of plain CS, together with a 46% increase in strength.