Fabrication of Metallic Biomedical Scaffolds with the Space Holder Method: A Review

Biomineral-Based Composite Materials in Regenerative Medicine

Regenerative medicine aims to address substantial defects by amplifying the body's natural regenerative abilities and preserving the health of tissues and organs. To achieve these goals, materials that can provide the spatial and biological support for cell proliferation and differentiation, as well as the micro-environment essential for the intended tissue, are needed. Scaffolds such as polymers and metallic materials provide three-dimensional structures for cells to attach to and grow in defects. These materials have limitations in terms of mechanical properties or biocompatibility. In contrast, biominerals are formed by living organisms through biomineralization, which also includes minerals created by replicating this process. Incorporating biominerals into conventional materials allows for enhanced strength, durability, and biocompatibility. Specifically, biominerals can improve the bond between the implant and tissue by mimicking the micro-environment. This enhances cell differentiation and tissue regeneration. Furthermore, biomineral composites have wound healing and antimicrobial properties, which can aid in wound repair. Additionally, biominerals can be engineered as drug carriers, which can efficiently deliver drugs to their intended targets, minimizing side effects and increasing therapeutic efficacy. This article examines the role of biominerals and their composite materials in regenerative medicine applications and discusses their properties, synthesis methods, and potential uses.

Review of recent advances in bone scaffold fabrication methods for tissue engineering for treating bone diseases and sport injuries

Despite advancements in medical care, the management of bone injuries remains one of the most significant challenges in the fields of medicine and sports medicine globally. Bone tissue damage is often associated with aging, reduced quality of life, and various conditions such as trauma, cancer, and infection. While bone tissue possesses the natural capacity for self-repair and regeneration, severe damage may render conventional treatments ineffective, and bone grafting may be limited due to secondary surgical procedures and potential disease transmission. In such cases, bone tissue engineering has emerged as a viable approach, utilizing cells, scaffolds, and growth factors to repair damaged bone tissue. This research shows a comprehensive review of the current literature on the most important and effective methods and materials for improving the treatment of these injuries. Commonly employed cell types include osteogenic cells, embryonic stem cells, and mesenchymal cells, while scaffolds play a crucial role in bone tissue regeneration. To create an effective bone scaffold, a thorough understanding of bone structure, material selection, and examination of scaffold fabrication techniques from inception to the present day is necessary. By gaining insights into these three key components, the ability to design and construct appropriate bone scaffolds can be achieved. Bone tissue engineering scaffolds are evaluated based on factors such as strength, porosity, cell adhesion, biocompatibility, and biodegradability. This article examines the diverse categories of bone scaffolds, the materials and techniques used in their fabrication, as well as the associated merits and drawbacks of these approaches. Furthermore, the review explores the utilization of various scaffold types in bone tissue engineering applications.

Forged to heal: The role of metallic cellular solids in bone tissue engineering

Metallic cellular solids, made of biocompatible alloys like titanium, stainless steel, or cobalt-chromium, have gained attention for their mechanical strength, reliability, and biocompatibility. These three-dimensional structures provide support and aid tissue regeneration in orthopedic implants, cardiovascular stents, and other tissue engineering cellular solids. The design and material chemistry of metallic cellular solids play crucial roles in their performance: factors such as porosity, pore size, and surface roughness influence nutrient transport, cell attachment, and mechanical stability, while their microstructure imparts strength, durability and flexibility. Various techniques, including additive manufacturing and conventional fabrication methods, are utilized for producing metallic biomedical cellular solids, each offering distinct advantages and drawbacks that must be considered for optimal design and manufacturing. The combination of mechanical properties and biocompatibility makes metallic cellular solids superior to their ceramic and polymeric counterparts in most load bearing applications, in particular under cyclic fatigue conditions, and more in general in application that require long term reliability. Although challenges remain, such as reducing the production times and the associated costs or increasing the array of available materials, metallic cellular solids showed excellent long-term reliability, with high survival rates even in long term follow-ups.

Magnesium-based alloys with adapted interfaces for bone implants and tissue engineering

Magnesium and its alloys are one of the most used materials for bone implants and tissue engineering. They are characterized by numerous advantages such as biodegradability, high biocompatibility and mechanical properties with values close to the human bone. Unfortunately, the implant surface must be adequately tuned, or Mg-based alloys must be alloyed with other chemical elements due to their increased corrosion effect in physiological media. This article reviews the clinical challenges related to bone repair and regeneration, classifying bone defects and presenting some of the most used and modern therapies for bone injuries, such as Ilizarov or Masquelet techniques or stem cell treatments. The implant interface challenges are related to new bone formation and fracture healing, implant degradation and hydrogen release. A detailed analysis of mechanical properties during implant degradation is extensively described based on different literature studies that included in vitro and in vivo tests correlated with material properties' characterization. Mg-based trauma implants such as plates and screws, intramedullary nails, Herbert screws, spine cages, rings for joint treatment and regenerative scaffolds are presented, taking into consideration their manufacturing technology, the implant geometrical dimensions and shape, the type of in vivo or in vitro studies and fracture localization. Modern technologies that modify or adapt the Mg-based implant interfaces are described by presenting the main surface microstructural modifications, physical deposition and chemical conversion coatings. The last part of the article provides some recommendations from a translational perspective, identifies the challenges associated with Mg-based implants and presents some future opportunities. This review outlines the available literature on trauma and regenerative bone implants and describes the main techniques used to control the alloy corrosion rate and the cellular environment of the implant.

Design of Ti64/Ta Hybrid Materials by Powder Metallurgy Mimicking Bone Structure

This work reports on the fabrication of a novel two-layer material composed of a porous tantalum core and a dense Ti6Al4V (Ti64) shell by powder metallurgy. The porous core was obtained by mixing Ta particles and salt space-holders to create large pores, the green compact was obtained by pressing. The sintering behavior of the two-layer sample was studied by dilatometry. The interface bonding between the Ti64 and Ta layers was analyzed by SEM, and the pore characteristics were analyzed by computed microtomography. Images showed that two distinct layers were obtained with a bonding achieved by the solid-state diffusion of Ta particles into Ti64 during sintering. The formation of β-Ti and α' martensitic phases confirmed the diffusion of Ta. The pore size distribution was in the size range of 80 to 500 µm, and a permeability value of 6 × 10^-10 m² was close to the trabecular bones one. The mechanical properties of the component were dominated mainly by the porous layer, and Young's modulus of 16 GPa was in the range of bones. Additionally, the density of this material (6 g/cm³) was much lower than the one of pure Ta, which helps to reduce the weight for the desired applications. These results indicate that structurally hybridized materials, also known as composites, with specific property profiles can improve the response to osseointegration for bone implant applications.

An Investigation into the Potential of Turning Induced Deformation Technique for Developing Porous Magnesium and Mg-SiO2 Nanocomposite

A new and novel method of synthesising porous Mg materials has been explored utilising a variant of a processing method previously used for the synthesis of dense Mg materials, namely the turning-induced deformation (TID) method combined with sintering. It was found that the Mg materials synthesised possessed comparable properties to previously-synthesised porous Mg materials in the literature while subsequent sintering resulted in a more consistent mechanical response, with microwave sintering showing the most promise. The materials were also found to possess mechanical response within the range of the human cancellous bone, and when reinforced with biocompatible silica nanoparticles, presented the most optimal combination of mechanical properties for potential use as biodegradable implants due to most similarity with cancellous bone properties.

Bioactive fluorcanasite reinforced magnesium alloy-based porous bio-nanocomposite scaffolds with tunable mechanical properties

Magnesium (Mg) alloy-based porous bio-nanocomposite bone scaffolds were developed by powder metallurgy route. Selective alloying elements such as calcium (Ca), zinc (Zn) and strontium (Sr) were incorporated to tune the mechanical integrity while, bioactive fluorcanasite nano-particulates were introduced within the alloy system to enhance the bone tissue regeneration. Green compacts containing carbamide were fabricated and sintered using two-stage heat treatment process to achieve the targeted porosities. The microstructure of these fabricated magnesium alloy-based bio-nanocomposites was examined by Field emission scanning electron microscope (FE-SEM) and x-ray micro computed tomography (x-ray μCT), which revealed gradient porosities and distribution of alloying elements. X-ray diffraction (XRD) studies confirmed the presence of major crystalline phases in the fabricated samples and the evolution of the various combinations of intermetallic phases of Ca, Mg, Zn and Sr which were anticipated to enhance the mechanical properties. Further, XRD studies revealed the presence of apatite phase for the immersed samples, a conducive environment for bone regeneration. The fabricated samples were evaluated for their mechanical performance against uniaxial compression load. The tunability of compressive strengths and modulus values could be established with variation in porosities of fabricated samples. The retained compressive strength and Young's modulus of the samples following immersion in phosphate buffered saline (PBS) solution was found to be in line with that of natural human cancellous bone, thereby establishing the potential of the fabricated magnesium-alloy-based nanocomposite as a promising scaffold candidate for bone tissue engineering.

Synthesis and characterization of gentamicin loaded ZSM-5 scaffold: Cytocompatibility and antibacterial activity

Porous structure, biocompatibility and biodegradability, large surface area, and drug-loading ability are some remarkable properties of zeolite structure, making it a great possible option for bone tissue engineering. Herein, we evaluated the potential application of the ZSM-5 scaffold encapsulated GEN with high porosity structure and significant antibacterial properties. The space holder process has been employed as a new fabrication method with interconnected pores and suitable mechanical properties. In this study, for the first time, ZSM-5 scaffolds with GEN drug-loading were fabricated with the space holder method. The results showed excellent open porosity in the range of 70-78% for different GEN concentrations and appropriate mechanical properties. Apatite formation on the scaffold surface was determined with Simulation body fluid (SBF), and a new bone-like apatite layer shaping on all samples confirmed the in vitro bioactivity of ZSM-5-GEN scaffolds. Also, antibacterial properties were investigated against both gram-positive and gram-negative bacteria. The incorporation of various amounts of GEN increased the inhibition zone from 24 to 28 (for E. coli) and 26 to 37 (for S. aureus). In the culture with MG63 cells, great cell viability and high cell proliferation after 7 days of culture were determined.

Experimental Analysis and Parametric Optimization on Compressive Properties of Diamond-Reinforced Porous Al Composites

The present study aims to optimize the compressive properties of porous aluminum composites fabricated using the powder metallurgy (PM) space holder technique. These properties were optimized by taking into consideration different processing factors such as sintering temperature, compaction pressure, and sintering time. The experimental design was formulated using L₉ orthogonal array by employing these three parameters at three levels. The density, porosity, plateau stress, and energy absorption capacity were determined and analyzed. The impact of individual input parameters was evaluated using the Taguchi-based S/N ratio and analysis of variance (ANOVA). The main effect plots outlined the optimum parameter levels to achieve maximum values for compressive properties (plateau stress and energy absorption capacity). The results revealed that the sintering temperature and time significantly impact compressive properties. The ANOVA analysis exhibited similar results, with maximum contribution from sintering temperature. Further response optimization of compressive properties concluded that the maximum values could be achieved at optimum parameters, i.e., a sintering temperature of 590 °C, compaction pressure of 350 MPa, and sintering time of 90 min. Further, confirmation tests on the optimized parameters revealed improved results and some minor errors and deviations indicating that the selected parameters are vital for controlling the compressive properties of the aluminum composites.

In vivo evaluation of osseointegration ability of sintered bionic trabecular porous titanium alloy as artificial hip prosthesis

Hydroxyapatite (HA) coatings have been widely used for improving the bone-implant interface (BII) bonding of the artificial joint prostheses. However, the incidence of prosthetic revisions due to aseptic loosening remains high. Porous materials, including three-dimensional (3D) printing, can reduce the elastic modulus and improve osseointegration at the BII. In our previous study, we identified a porous material with a sintered bionic trabecular structure with in vitro and in vivo bio-safety as well as in vivo mechanical safety. This study aimed to compare the difference in osseointegration ability of the different porous materials and HA-coated titanium alloy in the BII. We fabricated sintered bionic trabecular porous titanium acetabular cups, 3D-printed porous titanium acetabular cups, and HA-coated titanium alloy acetabular cups for producing a hip prosthesis suitable for beagle dogs. Subsequently, the imaging and histomorphological analysis of the three materials under mechanical loading in animals was performed (at months 1, 3, and 6). The results suggested that both sintered bionic porous titanium alloy and 3D-printed titanium alloy exhibited superior performances in promoting osseointegration at the BII than the HA-coated titanium alloy. In particular, the sintered bionic porous titanium alloy exhibited a favorable bone ingrowth performance at an early stage (month 1). A comparison of the two porous titanium alloys suggested that the sintered bionic porous titanium alloys exhibit superior bone in growth properties and osseointegration ability. Overall, our findings provide an experimental basis for the clinical application of sintered bionic trabecular porous titanium alloys.

Structural Characterization Analyses of Low Brass Filler Biomaterial for Hard Tissue Implanted Scaffold Applications

A biomaterial was created for hard tissue implanted scaffolds as a translational therapeutic approach. The existing biomaterials containing titanium dioxide filler posed a risk of oxygen gas vacancy. This will block the canaliculars, leading to a limit on the nutrient fluid supply. To overcome this problem, low brass was used as an alternative filler to eliminate the gas vacancy. Low brass with composition percentages of 0%, 2%, 5%, 15%, and 30% was filled into the polyester urethane liquidusing the metallic filler polymer reinforced method. The structural characterizations of the low brass filler biomaterial were investigated by Field Emission Scanning Electron Microscopy. The results showed the surface membrane strength was higher than the side and cross-section. The composition shapes found were hexagon for polyester urethane and peanut for low brass. Low brass stabilised polyester urethane in biomaterials by the formation of two 5-ringed tetrahedral crystal structures. The average pore diameter was 308.9 nm, which is suitable for articular cartilage cells. The pore distribution was quite dispersed, and its curve had a linear relationship between area and diameter, suggestive of the sphere-shaped pores. The average porosities were different between using FESEM results of 6.04% and the calculated result of 3.28%. In conclusion, this biomaterial had a higher surface membrane strength and rather homogeneous dispersed pore structures.

Low Mg content on Ti-Nb-Sn alloy when in contact with eBMMSCs promotes improvement of its biological functions

Magnesium is a metal used in the composition of titanium alloys and imparts porosity. Due to its osteoconductive, biocompatible and biodegradable characteristics, its application in the development of biomedical materials has become attractive. This study aimed to evaluate the influence of magnesium present in porous Ti-Nb-Sn alloys, which have a low elastic modulus in adhesive, osteogenic properties and the amount of reactive intracellular oxygen species released in mesenchymal stem cells derived from bone marrow equine bone (eBMMSCs). Mechanical properties of the alloy, such as hardness, compressive strength and elastic modulus, were analyzed, as well as surface morphological characteristics through scanning electron microscopy. The evaluation of magnesium ion release was performed by atomic force spectroscopy. The biological characteristics of the alloy, when in contact with the alloy surface and with the culture medium conditioned with the alloy, were studied by SEM and optical microscopy. Confirmation of osteogenic differentiation by alizarin red and detection of ROS using a Muse® Oxidative Stress Kit based on dihydroetide (DHE). The alloy showed an elastic modulus close to cortical bone values. The hardness was close to commercial Ti grade 2, and the compressive strength was greater than the value of cortical bone. The eBMMSCs adhered to the surface of the alloy during the experimental time. Osteogenic differentiation was observed with the treatment of eBMMMSCs with conditioned medium. The eBMMSCs treated with conditioned medium decreased ROS production, indicating a possible antioxidant defense potential of magnesium release.

Macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting

Cellular materials are recognized for their high specific mechanical properties, making them desirable in ultra-lightweight applications. Periodic lattices have tunable properties and may be manufactured by metallic additive manufacturing (AM) techniques. However, AM can lead to issues with un-melted powder, macro/micro porosity, dimensional control and heterogeneous microstructures. This study overcomes these problems through a novel technique, combining additive manufacturing and investment casting to produce detailed investment cast lattice structures. Fused filament fabrication is used to fabricate a pattern used as the mold for the investment casting of aluminium A356 alloy into high-conformity thin-ribbed (~ 0.6 mm thickness) scaffolds. X-ray micro-computed tomography (CT) is used to characterize macro- and meso-scale defects. Optical and scanning electron (SEM) microscopies are used to characterize the microstructure of the cast structures. Slight dimensional (macroscale) variations originate from the 3D printing of the pattern. At the mesoscale, the casting process introduces very fine (~ 3 µm) porosity, along with small numbers of (~ 25 µm) gas entrapment defects in the horizontal struts. At a microstructural level, both the (~ 70 μm) globular/dendritic grains and secondary phases show no significant variations across the lattices. This method is a promising alternative means for producing highly detailed non-stochastic metallic cellular lattices and offers scope for further improvement through refinement of filament fabrication.

Structural and Material Determinants Influencing the Behavior of Porous Ti and Its Alloys Made by Additive Manufacturing Techniques for Biomedical Applications

One of the biggest challenges in tissue engineering is the manufacturing of porous structures that are customized in size and shape and that mimic natural bone structure. Additive manufacturing is known as a sufficient method to produce 3D porous structures used as bone substitutes in large segmental bone defects. The literature indicates that the mechanical and biological properties of scaffolds highly depend on geometrical features of structure (pore size, pore shape, porosity), surface morphology, and chemistry. The objective of this review is to present the latest advances and trends in the development of titanium scaffolds concerning the relationships between applied materials, manufacturing methods, and interior architecture determined by porosity, pore shape, and size, and the mechanical, biological, chemical, and physical properties. Such a review is assumed to show the real achievements and, on the other side, shortages in so far research.

Corrosion and wear behaviour of highly porous Ti-TiB-TiNx in situ composites in simulated physiological solution

Highly porous Ti matrix composites can be a solution for some of the major clinical concerns for the load bearing implants such as low tribocorrosion resistance, stress shielding, and lack of biological anchorage. In order to respond to these needs, highly porous Ti-TiB-TiN_x in-situ composites were synthesized by pressureless sintering using BN as reactant and urea as space holder. Corrosion behaviour was investigated at body temperature, in phosphate buffer saline solution (PBS), by measuring open circuit potential (OCP) and cyclic polarization. Wear behaviour was studied in PBS by reciprocating against a 10 mm diameter alumina ball under 3 N of normal load and 1 Hz of frequency. Results showed that the formation of the in-situ reinforcing phases led to an increase on the hardness and on the wear resistance, as well, neither macro porosity nor the reinforcing phases led to localized corrosion.

Recent Development in Beta Titanium Alloys for Biomedical Applications

β-type titanium (Ti) alloys have attracted a lot of attention as novel biomedical materials in the past decades due to their low elastic moduli and good biocompatibility. This article provides a broad and extensive review of β-type Ti alloys in terms of alloy design, preparation methods, mechanical properties, corrosion behavior, and biocompatibility. After briefly introducing the development of Ti and Ti alloys for biomedical applications, this article reviews the design of β-type Ti alloys from the perspective of the molybdenum equivalency (Moeq) method and DV-Xα molecular orbital method. Based on these methods, a considerable number of β-type Ti alloys are developed. Although β-type Ti alloys have lower elastic moduli compared with other types of Ti alloys, they still possess higher elastic moduli than human bones. Therefore, porous β-type Ti alloys with declined elastic modulus have been developed by some preparation methods, such as powder metallurgy, additive manufacture and so on. As reviewed, β-type Ti alloys have comparable or even better mechanical properties, corrosion behavior, and biocompatibility compared with other types of Ti alloys. Hence, β-type Ti alloys are the more suitable materials used as implant materials. However, there are still some problems with β-type Ti alloys, such as biological inertness. As such, summarizing the findings from the current literature, suggestions forβ-type Ti alloys with bioactive coatings are proposed for the future development.

Multi-material additive manufacturing technologies for Ti-, Mg-, and Fe-based biomaterials for bone substitution

The growing interest in multi-functional metallic biomaterials for bone substitutes challenges the current additive manufacturing (AM, =3D printing) technologies. It is foreseeable that advances in multi-material AM for metallic biomaterials will not only allow for complex geometrical designs, but also improve their multi-functionalities by tuning the types or compositions of the underlying base materials, thereby presenting unprecedented opportunities for advanced orthopedic treatments. AM technologies are yet to be extensively explored for the fabrication of multi-functional metallic biomaterials, especially for bone substitutes. The aim of this review is to present the viable options of the state-of-the-art multi-material AM for Ti-, Mg-, and Fe-based biomaterials to be used as bone substitutes. The review starts with a brief review of bone tissue engineering, the design requirements, and fabrication technologies for metallic biomaterials to highlight the advantages of using AM over conventional fabrication methods. Five AM technologies suitable for metal 3D printing are compared against the requirements for multi-material AM. Of these AM technologies, extrusion-based multi-material AM is shown to have the greatest potential to meet the requirements for the fabrication of multi-functional metallic biomaterials. Finally, recent progress in the fabrication of Ti-, Mg-, and Fe-based biomaterials including the utilization of multi-material AM technologies is reviewed so as to identify the knowledge gaps and propose the directions of further research for the development of multi-material AM technologies that are applicable for the fabrication of multi-functional metallic biomaterials. STATEMENT OF SIGNIFICANCE: Addressing a critical bone defect requires the assistance of multi-functional porous metallic bone substitutes. As one of the most advanced fabrication technology in bone tissue engineering, additive manufacturing is challenged for its viability in multi-material fabrication of metallic biomaterials. This article reviews how the current metal additive manufacturing technologies have been and can be used for multi-material fabrication of Ti-, Mg-, and Fe-based bone substitutes. Progress on the Ti-, Mg-, and Fe-based biomaterials, including the utilization of multi-material additive manufacturing, are discussed to direct future research for advancing the multi-functional additively manufactured metallic bone biomaterials.

Applying Baghdadite/PCL/Chitosan Nanocomposite Coating on AZ91 Magnesium Alloy to Improve Corrosion Behavior, Bioactivity, and Biodegradability

Magnesium alloys have received a great amount of attention regarding being used in biomedical applications; however, they show high degradability, poor bioactivity, and biocompatibility. To improve these properties, surface modification and various types of coatings have been applied. In this study, an anodized AZ91 alloy was coated with a polymer matrix composite made of polycaprolactone/chitosan (PCL/Ch) with different percentages of baghdadite to improve its resistance to corrosion, bioactivity, and biocompatibility. The effects of different percentages of baghdadite (0 wt %, 1 wt %, 3 wt %, and 5 wt %) on the surface microstructure, corrosion resistance, roughness, and wettability were evaluated. The results indicated that the applied nano-polymer-ceramic coating including 3 wt % baghdadite was hydrophobic, which consequently increased the corrosion resistance and decreased the corrosion current density of the anodized AZ91 alloy. Coating with 3 wt % baghdadite increased the roughness of AZ91 from 0.329 ± 0.02 to 7.026 ± 0.31 μm. After applying the polymer-ceramic coating on the surface of anodized AZ91, the corrosion products changed into calcium–phosphate compounds instead of Mg(OH)2, which is more stable in a physiological environment.

The influence of polycaporolacton fumarate coating on mechanical properties and in vitro behavior of porous diopside-hardystonite nano-composite scaffold

One of the significant challenges in bone tissue engineering is the fabrication of highly porous scaffolds with interconnected pores and appropriate mechanical properties. Artificial scaffolds which used in the field of medicine are usually made of single phase of polymer or ceramic. However, composition of these materials can produce the scaffolds with improve mechanical and biological properties.The aim of this study is to synthesize three-dimensional hardystonite-diopside (HT-Dio) porous scaffolds modified by polycaporolacton fumarate coating for low-load-bearing bone tissue engineering applications. The results showed that hardystonite scaffolds with 15 wt. % diopside and 6 w/v % polymer polycaporolacton fumarate (PCLF) had a significant bioactivity. The cell culture and cell attachment assay results revealed the well spreading of BMS cells on the surface of modified scaffolds which indicates the high biocompatibility of this scaffold. The modified scaffolds had a mean pore size, porosity, compressive strength, modules and toughness of 293.47 ± 5.51 μm, 74% ± 1.01, 3.37 ± 0.6 MPa, 151 ± 1.1 MPa and 31.3 ± 0.32 kJ/m³, respectively, which are in the appropriate range for spongy bone and hence can be a good candidate for bone tissue engineering applications.

A Cold-Pressing Method Combining Axial and Shear Flow of Powder Compaction to Produce High-Density Iron Parts

Highly performance methods for cold pressing (cold die forging) of preforms from iron powder with subsequent heat treatment and producing ready parts made of powder are described in the paper. These methods allow fabricating parts with smooth surfaces and improved mechanical characteristics—porosity, tensile strength. Application of the traditional design set-up with a single-axial loading is restricted to high stresses in the dies to deform the preforms that lead to cracks formation. New powder compaction schemes by applying active friction forces (shear-enhanced compaction) make it possible to unload dies and produce high-quality parts by cold pressing. The scheme allows moving the die in the direction of the material flow with a velocity that exceeds the material flow velocity.

Engineered bio-nanocomposite magnesium scaffold for bone tissue regeneration

Porous magnesium based materials are gaining intensive potential as a substitute scaffold material in the field of biomedical engineering as their mechanical properties such as compressive strength and elastic modulus are quite similar to that of human bone. Considering the poor mechanical integrity of ceramic and polymeric materials, metallic implants such as magnesium based alloy foams can be used as a promising scaffold material for bone tissue engineering. Magnesium foams also have properties like excellent biocompatibility and biodegradability so that revision surgery can be completely eliminated after implantation in orthopaedic applications. Against this background, porous Mg alloy based bioactive nano-composite foams were developed. Nano-hydroxyapatite (n-HA) was used as bioactive reinforcement which was anticipated to enhance bone tissue regenerations. Magnesium based alloy compositions were developed by incorporating selective alloying elements, while the bioactive nano-composite foams were fabricated using powder metallurgy route. The powder metallurgy route involved sequential stages of mixing and compaction of all powders with carbamide powder as a space holding material, followed by sintering of the green compacts. The microstructures of these nano-ceramic reinforced metal matrix foams were studied by scanning electron microscopy (SEM) in combination with energy dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD) and X-ray micro computed tomography (X-ray micro CT). Further, mechanical properties of the nanocomposite foams were evaluated. SEM and EDS results confirmed a homogeneous distribution of pores, alloying elements and n-HA. Structure-property correlations were established through the microstructural characterizations. The study therefore demonstrated that selected Mg alloy based composite foam can be an excellent candidate material for bone tissue engineering.

Bioactive scaffolds for osteochondral regeneration

Treatment for osteochondral defects remains a great challenge. Although several clinical strategies have been developed for management of osteochondral defects, the reconstruction of both cartilage and subchondral bone has proved to be difficult due to their different physiological structures and functions. Considering the restriction of cartilage to self-healing and the different biological properties in osteochondral tissue, new therapy strategies are essential to be developed. This review will focus on the latest developments of bioactive scaffolds, which facilitate the osteogenic and chondrogenic differentiation for the regeneration of bone and cartilage. Besides, the topic will also review the basic anatomy, strategies and challenges for osteochondral reconstruction, the selection of cells, biochemical factors and bioactive materials, as well as the design and preparation of bioactive scaffolds. Specifically, we summarize the most recent developments of single-type bioactive scaffolds for simultaneously regenerating cartilage and subchondral bone. Moreover, the future outlook of bioactive scaffolds in osteochondral tissue engineering will be discussed. This review offers a comprehensive summary of the most recent trend in osteochondral defect reconstruction, paving the way for the bioactive scaffolds in clinical therapy.

THE TRANSLATIONAL POTENTIAL OF THIS ARTICLE

This review summaries the latest developments of single-type bioactive scaffolds for regeneration of osteochondral defects. We also highlight a new possible translational direction for cartilage formation by harnessing bioactive ions and propose novel paradigms for subchondral bone regeneration in application of bioceramic scaffolds.

Synthesis and characterization of a novel open cellular Mg-based scaffold for tissue engineering application

Tissue engineering is a field which aims to regenerate damaged tissues by enhancing tissue growth through the porous architecture of the scaffolds which is desired to mimic the human cancellous bone. Mg-based scaffolds are gaining importance in the field of tissue engineering owing to its potential application as a biomaterial. However, fabrication of porous Mg remains a daunting task due to its highly reactive nature. In the present work, a novel Mg-based open cell porous structure with pore interconnectivity and significant strength is successfully fabricated using powder metallurgy approach and Ti-woven wire mesh as a space holding material. Pore morphology and percentage porosity can be easily altered by adjusting the Ti-wire diameter and shape of construct. SEM, EDX and µ-CT analysis were performed to assess the microstructural properties of the fabricated scaffold which revealed a uniform distribution of pores with porosity varying in range 50-60%. The measured values of ultimate compressive strength and elastic modulus using quasi static compression test were found to be 101 MPa and 2 GPa, respectively. Further to improve corrosion resistance of fabricated scaffold, alloying and coating were carried out. Preliminary degradation study as well as cytocompatibility studies using L929 cells was carried out to validate the potential of fabricated scaffold for bone healing/repair applications. Fabricated porous structures showed improved corrosion resistance as well as cell viability of more than 90%, suggesting it as a promising development for bone scaffolding applications in future.

Design and Compressive Behavior of a Photosensitive Resin-Based 2-D Lattice Structure with Variable Cross-Section Core

This paper designed and manufactured photosensitive resin-based 2-D lattice structures with different types of variable cross-section cores by stereolithography 3D printing technology (SLA 3DP). An analytical model was employed to predict the structural compressive response and failure types. A theoretical calculation was performed to obtain the most efficient material utilization of the 2-D lattice core. A flatwise compressive experiment was performed to verify the theoretical conclusions. A comparison of theoretical and experimental results showed good agreement for structural compressive response. Results from the analytical model and experiments showed that when the 2-D lattice core was designed so that R/r = 1.167 (R and r represent the core radius at the ends and in the middle), the material utilization of the 2-D lattice core improved by 13.227%, 19.068%, and 22.143% when n = 1, n = 2, and n = 3 (n represents the highest power of the core cross-section function).

Novel fabrication of porous titanium by a resin-impregnated titanium substitution technique for bone reconstruction

The purpose of this study was to evaluate the characteristic structures and osteoconduction ability of porous titanium structures using a resin-impregnated titanium substitution fabrication technique.

Influence of the electrolyte's pH on the properties of electrochemically deposited hydroxyapatite coating on additively manufactured Ti64 alloy

Properties of the hydroxyapatite obtained by electrochemical assisted deposition (ED) are dependent on several factors including deposition temperature, electrolyte pH and concentrations, applied potential. All of these factors directly influence the morphology, stoichiometry, crystallinity, electrochemical behaviour, and particularly the coating thickness. Coating structure together with surface micro- and nano-scale topography significantly influence early stages of the implant bio-integration. The aim of this study is to analyse the effect of pH modification on the morphology, corrosion behaviour and in vitro bioactivity and in vivo biocompatibility of hydroxyapatite prepared by ED on the additively manufactured Ti64 samples. The coatings prepared in the electrolytes with pH = 6 have predominantly needle like morphology with the dimensions in the nanometric scale (~30 nm). Samples coated at pH = 6 demonstrated higher protection efficiency against the corrosive attack as compared to the ones coated at pH = 5 (~93% against 89%). The in vitro bioactivity results indicated that both coatings have a greater capacity of biomineralization, compared to the uncoated Ti64. Somehow, the coating deposited at pH = 6 exhibited good corrosion behaviour and high biomineralization ability. In vivo subcutaneous implantation of the coated samples into the white rats for up to 21 days with following histological studies showed no serious inflammatory process.

Preparing diopside nanoparticle scaffolds via space holder method: Simulation of the compressive strength and porosity

In the present study, diopside nanopowders were prepared via mechanical milling with eggshell as the calcium source. The space holder method (compaction of ceramic powder and spacer) as one of the most important methods to produce ceramic/metal scaffolds was used to produce diopside scaffolds. For the first time, the effect of the spacer size on mechanical properties and porosity of the obtained scaffolds was experimentally discussed. According to the results obtained, the NaCl particles (as the spacer) with the size of 400-600µm maintained their original spherical shape during the compaction and sintering processes. As a new work, the most important parameters including the spacer type, spacer concentration, spacer size, and applied pressure were considered, and their effects on mechanical properties and porosity of diopside scaffolds were simulated. Gene Expression Programming (GEP), as one of the most branches of the artificial intelligence, was used for simulation process. By using the GEP, two equations were introduced to predict the compressive strength and porosity of the obtained scaffolds with the lowest error values. The 3D diagrams extracted from the model were used to evaluate the combined effect of the process parameters on the compressive strength and porosity of the scaffolds. The GEP model presented in this work has a very low level of error and a high level of the squared regression for predicting the compressive strength and porosity of diopside scaffolds.

Diametral compression behavior of biomedical titanium scaffolds with open, interconnected pores prepared with the space holder method

Scaffolds with open, interconnected pores and appropriate mechanical properties are required to provide mechanical support and to guide the formation and development of new tissue in bone tissue engineering. Since the mechanical properties of the scaffold tend to decrease with increasing porosity, a balance must be sought in order to meet these two conflicting requirements. In this research, open, interconnected pores and mechanical properties of biomedical titanium scaffolds prepared by using the space holder method were characterized. Micro-computed tomography (micro-CT) and permeability analysis were carried out to quantify the porous structures and ascertain the presence of open, interconnected pores in the scaffolds fabricated. Diametral compression (DC) tests were performed to generate stress-strain diagrams that could be used to determine the elastic moduli and yield strengths of the scaffolds. Deformation and failure mechanisms involved in the DC tests of the titanium scaffolds were examined. The results of micro-CT and permeability analyses confirmed the presence of open, interconnected pores in the titanium scaffolds with porosity over a range of 31-61%. Among these scaffolds, a maximum specific surface area could be achieved in the scaffold with a total porosity of 5-55%. DC tests showed that the titanium scaffolds with elastic moduli and yield strengths of 0.64-3.47GPa and 28.67-80MPa, respectively, could be achieved. By comprehensive consideration of specific surface area, permeability and mechanical properties, the titanium scaffolds with porosities in a range of 50-55% were recommended to be used in cancellous bone tissue engineering.

Fabrication and Compressive Properties of Low to Medium Porosity Closed-Cell Porous Aluminum Using PMMA Space Holder Technique

In recent years, closed-cell porous Aluminum (Al) has drawn increasing attention, particularly in the applications requiring reduced weight and energy absorption capability such as in the automotive and aerospace industries. In the present work, porous Al with closed-cell structure was successfully fabricated by powder metallurgy technique using PMMA as a space holder. The effects of the amount of PMMA powder on the porosity, density, microstructure and compressive behaviors of the porous specimens were systematically evaluated. The results showed that closed-cell porous Al having different porosities (12%-32%) and densities (1.6478 g/cm³, 1.5125 g/cm³ and 1.305 g/cm³) could be produced by varying the amount of PMMA (20-30 wt %). Meanwhile, the compressive behavior results demonstrated that the plateau stress decreased and the energy absorption capacity increased with increasing amount of PMMA. However, the maximum energy absorption capacity was achieved in the closed-cell porous Al with the addition of 25 wt % PMMA. Therefore, fabrication of closed-cell porous Al using 25 wt % PMMA is considered as the optimal condition in the present study since the resultant closed-cell porous Al possessed good combinations of porosity, density and plateau stress, as well as energy absorption capacity.

Bone ingrowth of various porous titanium scaffolds produced by a moldless and space holder technique: an in vivo study in rabbits

Porous titanium has long been desired as a bone substitute material because of its ability to reduce the stress shielding in supporting bone. In order to achieve the various pore structures, we have evolved a moldless process combined with a space holder technique to fabricate porous titanium. This study aims to evaluate which pore size is most suitable for bone regeneration using our process. The mixture comprising Ti powder, wax binder and PMMA spacer was prepared manually at 70 °C which depended on the mixing ratio of each group. Group 1 had an average pore size of 60 μm, group 2 had a maximum pore size of 100 μm, group 3 had a maximum pore size of 200 μm and group 4 had a maximum pore size of 600 μm. These specimens were implanted into rabbit calvaria for three and 20 weeks. Thereafter, histomorphometrical evaluation was performed. In the histomorphometrical evaluation after three weeks, the group with a 600 μm pore size showed a tendency to greater bone ingrowth. However, after 20 weeks the group with a pore size of 100 μm showed significantly greater bone ingrowth than the other groups. This study suggested that bone regeneration into porous titanium scaffolds is pore size-dependent, while bone ingrowth was most prominent for the group with 100 μm-sized pores after 20 weeks in vivo.

Biocompatibility and compressive properties of Ti-6Al-4V scaffolds having Mg element

Porous scaffolds of Ti-6Al-4V were produced by mixing of this alloy with different amount of magnesium (Mg) powders. The mixtures were compacted in steel die by applying uniaxial pressure of 500 MPa before sintering the compacts in sealed quartz tubes at 900 °C for 2 h. Employing Archimedes׳ principle and Image Tool software, the total and open volume percentages of porosities within the scaffolds were found to be in the range of 47-64% and 41-47%, respectively. XRD results of titanium before and after sintering showed that no contamination, neither oxides nor nitrides formed during processes. Compressive properties of the scaffolds were studied using an Instron machine. The observed compressive strength and Young׳s module of the scaffolds were in the range of 72-132 MPa, and 37-47 GPa, respectively. Cell attachment and proliferation rate of MG-63 on porous samples were investigated. The results showed that proliferation rate increased with increasing Mg content. However no clear differences were observed between samples regarding cell attachment, so that bridges were observed in all cell gaps within the scaffolds.