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A DLP-Printed 3D Bioceramplug Fabricated Using a Photocurable Negative Thermo-Responsive Bioceramic Slurry for
Yu-Feng Su1,2,3,4, Chih-Yun Lee4,5,6, Yen-Han Lai4,5,7
1Division of Neurosurgery, Department of Surgery, Kaohsiung Medical University Hospital, Kaohsiung Medical University, Kaohsiung 807378, Taiwan.
ACS Biomaterials Science & Engineering
|July 3, 2026
Summary
This study introduces a 3D-printed beta-tricalcium phosphate (β-TCP) scaffold for cranial defect repair. The 3D Bioceramplug shows excellent mechanical stability, bone integration, and biocompatibility in animal models.
Area of Science:
- Biomaterials Science
- Regenerative Medicine
- Orthopedic Surgery
Background:
- Calcium phosphate (CaP) bioceramics are underutilized in cranioplasty due to brittleness and poor fixation.
- Existing limitations hinder stable host-implant coupling for cranial defect repair.
Purpose of the Study:
- To develop and evaluate a 3D-printed β-tricalcium phosphate (β-TCP) scaffold (3D Bioceramplug) for enhanced mechanical reliability, controlled resorption, and osteointegration in calvarial defects.
- To assess the scaffold's performance in preclinical animal models, including large-animal translational evaluation.
Main Methods:
- Digital Light Processing (DLP) printing using a thermo-responsive poly(N-isopropylacrylamide) (PNIPAM)-based ceramic slurry to create scaffolds with controlled porosity and high densification.
- Evaluation in rabbit critical-size calvarial defects using micro-CT and histology.
- Large-animal (pig) calvarial defect model for translational assessment, including blood biochemistry, CT/micro-CT, and histological analysis.
Main Results:
- The 3D Bioceramplug achieved high compressive strength (∼38 MPa) and rapid dewatering for accelerated manufacturing.
- Preclinical studies showed preserved structural integrity, significant osteoid ingrowth, and intramembranous ossification-mediated osteointegration.
- Translational studies demonstrated synchronized scaffold degradation with progressive bone formation, achieving 70-80% defect occupancy by new bone, alongside systemic biocompatibility and minimal inflammation.
Conclusions:
- The 3D Bioceramplug offers a mechanically stable, biologically safe, and osteoconductive platform for long-term cranial defect reconstruction.
- This novel approach provides an accelerated and personalized manufacturing route for sintered bioceramic bone substitutes.
- The 3D Bioceramplug represents a promising advancement for cranioplasty and calvarial reconstruction.
