Parametric Modeling of Biomimetic Cortical Bone Microstructure for Additive Manufacturing

3D printed polycaprolactone/β-tricalcium phosphate/carbon nanotube composite - Physical properties and biocompatibility

Three-dimensional (3D) printing is a bio-fabrication technique used to process tissue-engineered scaffolds for bone repair and remodeling. Polycaprolactone (PCL)/β-tricalcium phosphate (TCP) has been used as a base and osteoconductive biomaterial for bone tissue engineering in the past decades. The current study reveals the fabrication of a polycaprolactone (PCL)/β-tricalcium phosphate (TCP) scaffold by incorporating carbon nanotubes (CNT) via 3D printing. The physical properties and cytocompatibility of a new type of tissue engineering composite from polycaprolactone/β-tri-calcium phosphate/carbon nanotubes were investigated, and it was an absorbable scaffold prepared via furnace deposition 3D printing technology. The scaffold was designed with CAD software, and the composite material was fabricated via 3D printing. The printed composite material was tested for mechanical strength, scanning electron microscope (SEM) analysis, porosity calculation, systemic toxicity test, hemolysis rate determination, and effect on the proliferation of rat adipose-derived stem cells cultured in vitro. A composite scaffold with a length of 15 mm, width of 10 mm, and height of 5 mm was manufactured through CAD software drawing and 3D printing technology. Scanning electron microscopy measurements and analysis of the internal pore size of the stent are appropriate; the pores are interconnected, and the mechanical strength matches the strength of human cancellous bone. The calculated porosity of the stent was >60%, non-toxic, and non-hemolytic. The proliferation activity of the ADSC co-cultured with different scaffold materials was as follows: polycaprolactone/β-tricalcium phosphate/0.2% carbon nanotube scaffolds > polycaprolactone/β-tricalcium phosphate/0.1% carbon nanotube scaffolds > polycaprolactone/β-tricalcium phosphate/0.3% carbon nanotube scaffolds > polycaprolactone/β-tricalcium phosphate scaffolds (P < 0.05). The results showed that polycaprolactone/β-tricalcium phosphate/0.2% carbon nanotube scaffolds promoted the adhesion and proliferation of ADSC. The combination of 3D printing technology and CAD software can be used to print personalized composite stents, which have the characteristics of repeatability, high precision, and low cost. Through 3D printing technology, combining a variety of materials with each other can provide the greatest advantages of materials. The waste of resources was avoided. The prepared polycaprolactone/β-tri-calcium phosphate/0.2% carbon nanotube scaffold has a good pore structure and mechanical properties that mimic human cancellous bone, is non-toxic and non-hemolytic, and is effective in promoting ADSC proliferation in vitro. Given this correspondence, 3D printed scaffold shows good biocompatibility and strength, and the fabrication method provides a proof of concept for developing scaffolds for bone tissue engineering applications.

Aligned Ice Templated Biomaterial Strategies for the Musculoskeletal System

Aligned pore structures present many advantages when conceiving biomaterial strategies for treatment of musculoskeletal disorders. Aligned ice templating (AIT) is one of the many different techniques capable of producing anisotropic porous scaffolds; its high versatility allows for the formation of structures with tunable pore sizes, as well as the use of many different materials. AIT has been found to yield improved compressive properties for bone tissue engineering (BTE), as well as higher tensile strength and optimized cellular alignment and proliferation in tendon and muscle repair applications. This review evaluates the work that has been done in the last decade toward the production of aligned pore structures by AIT with an outlook on the musculoskeletal system. This work describes the fundamentals of the AIT technique and focuses on the research carried out to optimize the biomechanical properties of scaffolds by modifying the pore structure, categorizing by material type and application. Related topics including growth factor incorporation into AIT scaffolds, drug delivery applications, and studies about immune system response will be discussed.

Bioengineering Composite Aerogel-Based Scaffolds That Influence Porous Microstructure, Mechanical Properties and In Vivo Regeneration for Bone Tissue Application

Tissue regeneration of large bone defects is still a clinical challenge. Bone tissue engineering employs biomimetic strategies to produce graft composite scaffolds that resemble the bone extracellular matrix to guide and promote osteogenic differentiation of the host precursor cells. Aerogel-based bone scaffold preparation methods have been increasingly improved to overcome the difficulties in balancing the need for an open highly porous and hierarchically organized microstructure with compression resistance to withstand bone physiological loads, especially in wet conditions. Moreover, these improved aerogel scaffolds have been implanted in vivo in critical bone defects, in order to test their bone regeneration potential. This review addresses recently published studies on aerogel composite (organic/inorganic)-based scaffolds, having in mind the various cutting-edge technologies and raw biomaterials used, as well as the improvements that are still a challenge in terms of their relevant properties. Finally, the lack of 3D in vitro models of bone tissue for regeneration studies is emphasized, as well as the need for further developments to overcome and minimize the requirement for studies using in vivo animal models.

Predictive Modeling of Soft Stretchable Nanocomposites Using Recurrent Neural Networks

Human skin is characterized by rough, elastic, and uneven features that are difficult to recreate using conventional manufacturing technologies and rigid materials. The use of soft materials is a promising alternative to produce devices that mimic the tactile capabilities of biological tissues. Although previous studies have revealed the potential of fillers to modify the properties of composite materials, there is still a gap in modeling the conductivity and mechanical properties of these types of materials. While traditional Finite Element approximations can be used, these methodologies tend to be highly demanding of time and processing power. Instead of this approach, a data-driven learning-based approximation strategy can be used to generate prediction models via neural networks. This paper explores the fabrication of flexible nanocomposites using polydimethylsiloxane (PDMS) with different single-walled carbon nanotubes (SWCNTs) loadings (0.5, 1, and 1.5 wt.%). Simple Recurrent Neural Networks (SRNN), Long Short-Term Memory (LSTM), and Gated Recurrent Units (GRU) models were formulated, trained, and tested to obtain the predictive sequence data of out-of-plane quasistatic mechanical tests. Finally, the model learned is applied to a dynamic system using the Kelvin-Voight model and the phenomenon known as the bouncing ball. The best predictive results were achieved using a nonlinear activation function in the SRNN model implementing two units and 4000 epochs. These results suggest the feasibility of a hybrid approach of analogy-based learning and data-driven learning for the design and computational analysis of soft and stretchable nanocomposite materials.

An analytical and numerical approach to the determination of thermal necrosis in cortical bone drilling

In the process of repairing fractures in the bone region with orthopedic injuries, the application of supporting and strengthening the bone tissue with screws, wires, rods, and plates is a widely preferred internal fixation method. In this treatment process, it is necessary to drill the bone tissue to fix the screws. Due to the heat generated in the drilling process, mechanical and thermal damage occurs in the bone tissue. In this study, it is focused that the effect of different cutting conditions on the temperature distribution and necrosis zones in the drilling of human cortical bone. In this context, by selecting variable drill geometry (diameter, point angle, and helix angle) and variable cutting parameters (cutting speed and feed rate), temperature distribution and necrosis zones were investigated with finite element analyses and analytical calculations. When the findings were evaluated, it was understood that drill diameter and cutting speed did not have a significant effect on temperatures and necrosis zone at low cutting speeds. At high cutting speeds, it was observed that the feed rate and drill point angle had an indeterminate effect on the temperatures. The lowest temperature values were obtained at cutting speed of 750 rpm and a feed rate of 0.1 mm/rev for low cutting speeds, and cutting speed of 1500 rpm, helix angle of 10° and drill bit diameter of 2 mm for high cutting speeds. The narrowest necrosis zones were obtained at cutting speed of 250 rpm and feed rate of 0.1 mm/rev for both drill diameters. As a result, the effects of different drill geometry and cutting parameters were determined in order to obtain low temperature distribution and narrow necrosis zone in cortical bone drilling.

A review on bioceramics scaffolds for bone defect in different types of animal models: HA and β -TCP

Increased life expectancy has led to an increase in the use of bone substitutes in numerous nations, with over two million bone-grafting surgeries performed worldwide each year. A bone defect can be caused by trauma, infections, and tissue resections which can self-heal due to the osteoconductive nature of the native extracellular matrix components. However, natural self-healing is time-consuming, and new bone regeneration is slow, especially for large bone defects. It also remains a clinical challenge for surgeons to have a suitable bone substitute. To date, there are numerous potential treatments for bone grafting, including gold-standard autografts, allograft implantation, xenografts, or bone graft substitutes. Tricalcium phosphate (TCP) and hydroxyapatite (HA) are the most extensively used and studied bone substitutes due to their similar chemical composition to bone. The scaffolds should be testedin vivoandin vitrousing suitable animal models to ensure that the biomaterials work effectively as implants. Hence, this article aims to familiarize readers with the most frequently used animal models for biomaterials testing and highlight the available literature for in vivo studies using small and large animal models. This review summarizes the bio ceramic materials, particularly HA and β-TCP scaffolds, for bone defects in small and large animal models. Besides, the design considerations for the pre-clinical animal model selection for bone defect implants are emphasized and presented.

Correlation of Bone Material Model Using Voxel Mesh and Parametric Optimization

The authors present an algorithm for determining the stiffness of the bone tissue for individual ranges of bone density. The paper begins with the preparation and appropriate mechanical processing of samples from the bovine femur and their imaging using computed tomography and then processing DICOM files in the MIMICS system. During the processing of DICOM files, particular emphasis was placed on defining basic planes along the sides of the samples, which improved the representation of sample geometry in the models. The MIMICS system transformed DICOM images into voxel models from which the whole bone FE model was built in the next step. A single voxel represents the averaged density of the real sample in a very small finite volume. In the numerical model, it is represented by the HEX8 element, which is a cube. All voxels were divided into groups that were assigned average equivalent densities. Then, the previously prepared samples were loaded to failure in a three-point bending test. The force waveforms as a function of the deflection of samples were obtained, based on which the global stiffness of the entire sample was determined. To determine the stiffness of each averaged voxel density value, the authors used advanced optimization analyses, during which numerical analyses were carried out simultaneously, independently mapping six experimental tests. Ultimately, the use of genetic algorithms made it possible to select a set of stiffness parameters for which the error of mapping the global stiffness for all samples was the smallest. The discrepancies obtained were less than 5%, which the authors considered satisfactory by the authors for such a heterogeneous medium and for samples collected from different parts of the bone. Finally, the determined data were validated for the sample that was not involved in the correlation of material parameters. The stiffness was 7% lower than in the experimental test.

A Biomimetic Design Method for 3D-Printed Lightweight Structures Using L-Systems and Parametric Optimization

Biological structures and organisms are determined and optimized to adapt to changes and constraints imposed by the environment. The multiple functionalities and properties exhibited by such structures are currently a source of inspiration for designers and engineers. Thus, biomimetic design has been increasingly used in recent years with the intensive development of additive manufacturing to deliver innovative solutions. Due to their multifunctional properties combining softness, high stiffness, and light weight, many potential applications can be seen in the medical, aerospace, and automotive sectors. This paper introduces a biomimetic design and geometric modeling method of 3D-printed lightweight structures based on L-systems generated and distributed along their principal stress lines. Numerical simulations and parametric optimization were conducted with three case studies to demonstrate the relevance and applicability of this method in adapting mechanical structures to various load cases as well as ensuring a proper stiffness-to-weight ratio.

New Horizons for Hydroxyapatite Supported by DXA Assessment-A Preliminary Study

Dual Energy X-ray Absorptiometry (DXA) is a tool that allows the assessment of bone density. It was first presented by Cameron and Sorenson in 1963 and was approved by the Food and Drug Administration. Misplacing the femoral neck box, placing a trochanteric line below the midland and improper placement of boundary lines are the most common errors made during a DXA diagnostic test made by auto analysis. Hydroxyapatite is the most important inorganic component of teeth and bone tissue. It is estimated to constitute up to 70% of human bone weight and up to 50% of its volume. Calcium phosphate comes in many forms; however, studies have shown that only tricalcium phosphate and hydroxyapatite have the characteristics that allow their use as bone-substituted materials. The purpose of this study is aimed at analyzing the results of hip densitometry and hydorxyapatite distribution in order to better assess the structure and mineral density of the femoral neck. However, a detailed analysis of the individual density curves shows some qualitative differences that may be important in assessing bone strength in the area under study. To draw more specific conclusions on the therapy applied for individual patients, we need to determine the correct orientation of the bone from the resulting density and document the trends in the density distribution change. The average results presented with the DXA method are insufficient.

An original method of simulating the articular cartilage in the context of in vitro biomechanical studies investigating the proximal femur

Biomechanical testing is a necessity given the development of novel implants used in the osteosynthesis of hip fractures. The purpose of biomechanical testing is to recreate realistic conditions similar to the in vivo conditions. Although biomechanical testing of hip arthroplasty has been standardized since the 1970s, there is no consensus at present on testing methodology for osteosynthesis of hip fractures. Most biomechanical studies examining the fractures of the proximal femur in order to optimize implants opt for loading the bone-implant ensemble directly on the femoral head or using a metallic loading part. This loading technique fails to perform a mechanical stress distribution similar to in vivo conditions, which could alter the outcome. The present study aimed to design loading/unloading cups with mechanical properties that resemble those of the cartilage at the hip level. Through the impression and scanning of the cast models obtained, a digital 3D model was created in STL format and this was processed in order to obtain the computer numerical control (CNC) trajectories of the printing head. For prototyping using additive manufacturing technology, a thermoplastic polymer with biochemical properties, such as tensile strength, that resemble those of the adult hip and a Stratasys FORTUS 250 mc CNC machine were used. Loading/unloading cups with similar anatomy and biomechanical forces compared with those of the adult hip were created, which allowed the experimental simulation of the conditions during walking.

A Review on Development of Bio-Inspired Implants Using 3D Printing

Biomimetics is an emerging field of science that adapts the working principles from nature to fine-tune the engineering design aspects to mimic biological structure and functions. The application mainly focuses on the development of medical implants for hard and soft tissue replacements. Additive manufacturing or 3D printing is an established processing norm with a superior resolution and control over process parameters than conventional methods and has allowed the incessant amalgamation of biomimetics into material manufacturing, thereby improving the adaptation of biomaterials and implants into the human body. The conventional manufacturing practices had design restrictions that prevented mimicking the natural architecture of human tissues into material manufacturing. However, with additive manufacturing, the material construction happens layer-by-layer over multiple axes simultaneously, thus enabling finer control over material placement, thereby overcoming the design challenge that prevented developing complex human architectures. This review substantiates the dexterity of additive manufacturing in utilizing biomimetics to 3D print ceramic, polymer, and metal implants with excellent resemblance to natural tissue. It also cites some clinical references of experimental and commercial approaches employing biomimetic 3D printing of implants.

Characterization of Soft Tooling Photopolymers and Processes for Micromixing Devices with Variable Cross-Section

In this paper, we characterized an assortment of photopolymers and stereolithography processes to produce 3D-printed molds and polydimethylsiloxane (PDMS) castings of micromixing devices. Once materials and processes were screened, the validation of the soft tooling approach in microfluidic devices was carried out through a case study. An asymmetric split-and-recombine device with different cross-sections was manufactured and tested under different regime conditions (10 < Re < 70). Mixing performances between 3% and 96% were obtained depending on the flow regime and the pitch-to-depth ratio. The study shows that 3D-printed soft tooling can provide other benefits such as multiple cross-sections and other potential layouts on a single mold.

Biologically Inspired Collagen/Apatite Composite Biomaterials for Potential Use in Bone Tissue Regeneration-A Review

Type I collagen and nanocrystalline-substituted hydroxyapatite are the major components of a natural composite—bone tissue. Both of these materials also play a significant role in orthopedic surgery and implantology; however, their separate uses are limited; apatite is quite fragile, while collagen’s mechanical strength is very poor. Therefore, in biomaterial engineering, a combination of collagen and hydroxyapatite is used, which provides good mechanical properties with high biocompatibility and osteoinduction. In addition, the porous structure of the composites enables their use not only as bone defect fillers, but also as a drug release system providing controlled release of drugs directly to the bone. This feature makes biomimetic collagen–apatite composites a subject of research in many scientific centers. The review focuses on summarizing studies on biological activity, tested in vitro and in vivo.

3D printing of Haversian bone-mimicking scaffolds for multicellular delivery in bone regeneration

The integration of structure and function for tissue engineering scaffolds is of great importance in mimicking native bone tissue. However, the complexity of hierarchical structures, the requirement for mechanical properties, and the diversity of bone resident cells are the major challenges in constructing biomimetic bone tissue engineering scaffolds. Herein, a Haversian bone-mimicking scaffold with integrated hierarchical Haversian bone structure was successfully prepared via digital laser processing (DLP)-based 3D printing. The compressive strength and porosity of scaffolds could be well controlled by altering the parameters of the Haversian bone-mimicking structure. The Haversian bone-mimicking scaffolds showed great potential for multicellular delivery by inducing osteogenic, angiogenic, and neurogenic differentiation in vitro and accelerated the ingrowth of blood vessels and new bone formation in vivo. The work offers a new strategy for designing structured and functionalized biomaterials through mimicking native complex bone tissue for tissue regeneration.

Advances in bioprinting using additive manufacturing

Since its conception in the 1980's, several advances in the field of additive manufacturing have led to exploration of alternate as well as combination biomaterials. These progresses have directed the use of 3D printing in wider applications such as printing of dermal layers, cartilage, bone defects, and surgical implants. Furthermore, the incorporation of live and functional cells with or atop biomaterials has laid the foundation for its use in tissue engineering. The purpose of this review is to summarize the advances in 3D printing and bioprinting of several types of tissues such as skin, cartilage, bones, and cardiac valves. This review will address the current 3D technologies used in tissue construction and study the biomaterials being investigated. There are several requirements that need to be addressed, in order to reconstruct functional tissue such as mechanical strength, porosity of the replicate and cellular incorporation. Researchers have focused their studies to answer questions regarding these requirements.