3D Printing of Bioactive Glass-Poly(ε-Caprolactone) Scaffolds for Patient-Specific Bone Implants

Area of Science:

• Biomaterials Science
• Regenerative Medicine
• Craniofacial Surgery

Background:

• Craniofacial bone reconstruction is challenging due to complex anatomy and functional/aesthetic demands.
• Existing methods often struggle to fully restore structural integrity and appearance.
• Novel osteoconductive materials are needed for improved bone regeneration.

Purpose of the Study:

• To develop and characterize a 3D-printable bioactive glass-polymer composite for craniofacial patient-specific implants (PSIs).
• To evaluate the composite's printability, mechanical properties, and osteogenic potential.
• To assess the material's suitability for enhancing bone regeneration in craniofacial defects.

Main Methods:

• Fabrication of bioactive glass ceramic (BGS-7)/poly(ε-caprolactone) (PCL) composites via extrusion-based 3D printing at various ratios (2:8 to 5:5).
• Optimization of printing parameters for each formulation.
• Characterization using SEM/EDX, mechanical testing (compressive, flexural, tensile), and in vitro biological evaluation with human placental stem cells.

Main Results:

• Higher BGS-7 content improved phosphate, silicon, and calcium incorporation, enhancing mechanical properties and osteogenic potential.
• Composites supported high cell viability, adhesion, and spreading.
• Osteogenic differentiation was confirmed by calcium deposition and marker upregulation.
• The 5:5 BGS-7/PCL formulation showed optimal printability, bioactivity, and was used for human-scale structures.

Conclusions:

• The BGS-7/PCL composite, particularly the 5:5 ratio, demonstrates excellent printability and bioactivity for craniofacial PSI applications.
• This material platform shows significant potential for enhancing bone regeneration and restoring function in craniofacial defects.
• The study highlights a promising osteoconductive and biocompatible solution for complex craniofacial reconstructions.