Tailored Bioactive Glass Coating: Navigating Devitrification Toward a Superior Implant Performance

The development of well-adherent, amorphous, and bioactive glass coatings for metallic implants remains a critical challenge in biomedical engineering. Traditional bioactive glasses are susceptible to crystallization and exhibit a thermal expansion mismatch with implant materials. This study introduces a novel approach to overcome these limitations by employing systematic Na₂O substitution with CaO in borosilicate glasses. In-depth structural analysis (MD simulations, Raman spectroscopy, and NMR) reveals a denser network with smaller silicate rings, enhancing thermal stability, reducing thermal expansion, and influencing dissolution kinetics. This tailored composition exhibited optimal bioactivity (in vitro formation of bone-like apatite within 3 days) and a coefficient of thermal expansion closely matching Ti-6Al-4V, a widely used implant material. Furthermore, a consolidation process, meticulously designed with insights from crystallization kinetics and the viscosity-temperature relationship, yielded a crack-free, amorphous coating on Ti-6Al-4V substrates. This novel coating demonstrates excellent cytocompatibility and strong antibacterial action, suggesting superior clinical potential compared with existing technologies.