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A combined additive manufacturing and micro-syringe deposition technique for realization of bio-ceramic structures with micro-scale channels

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Abstract

This article presents a novel rapid layered manufacturing approach based on a combined additive manufacturing (AM) process and a UV-based micro-syringe deposition (μSD) technique to be used in the fabrication of bio-ceramic structures with controlled micro-sized channels for bone and osteochondral tissue regeneration. In the proposed rapid manufacturing method, micro-scale sacrificial photopolymer networks are integrated within the manufactured part by depositing the photopolymer on selected bio-ceramic powder layers using an injection system. This AM–μSD method along with a post-processing protocol can potentially overcome current limitations of traditional powder-based AM approaches that are restricted in terms of complexity of internal architecture and feature size. For bone or osteochondral repair applications, the material system composed of the bio-ceramic and sacrificial photopolymer, along with the post-processing protocol, must ensure that the final implants are free from manufacturing residuals that could trigger an immune response post-implantation. In this study, calcium polyphosphate bio-ceramic was used as the substrate material based on prior art, polyvinyl alcohol solution was used as the powder binding agent, and ethoxylated (10 bisphenol A diacrylate) photopolymer solution was used as the sacrificial photopolymer element. Material characterization suggests that the proposed material system along with heat treatment protocol is suitable for the targeted applications where micro-scale channels within the implant are produced by AM–μSD.

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Authors and Affiliations

  1. Department of Mechanical and Mechatronics Engineering, University of Waterloo, 200 University Ave. West, Waterloo, ON, N2L 3G1, Canada

    Mihaela Vlasea & Ehsan Toyserkani

  2. Department of Orthopedic Surgery, Stanford University, Stanford, CA, 94305, USA

    Yaser Shanjani

  3. Hamburg University of Technology, Schwarzenbergstrasse 95, Hamburg, 21073, Germany

    Annabel Bothe

  4. CIHR-Bioengineering of Skeletal Tissues Team, Mount Sinai Hospital, Toronto, ON, M5G1X5, Canada

    Rita Kandel

Authors
  1. Mihaela Vlasea
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  2. Yaser Shanjani
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  3. Annabel Bothe
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  4. Rita Kandel
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  5. Ehsan Toyserkani
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Corresponding author

Correspondence to Ehsan Toyserkani.

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Vlasea, M., Shanjani, Y., Bothe, A. et al. A combined additive manufacturing and micro-syringe deposition technique for realization of bio-ceramic structures with micro-scale channels. Int J Adv Manuf Technol 68, 2261–2269 (2013). https://doi.org/10.1007/s00170-013-4839-7

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  • DOI: https://doi.org/10.1007/s00170-013-4839-7

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