Component having a mineralised polymer structure and method for the production thereof

Abstract

In a method for producing a mineralised polymer component, a support structure (1) made of a polymer-based material is formed on the basis of an image data set, wherein the support structure (1) has at least one first region (5), in which the polymer-based material is formed, and at least one second region (2), which is designed as a hollow structure. Subsequently, at least one inorganic mineral phase is formed on the surface of the support structure (1) and / or within the first region (5) and / or on at least one inner surface of the first region (5).

Description

[0001] Component with a mineralized polymer structure and a method for its production

[0002] The present invention relates to a mineralized polymer component and a method for producing a mineralized polymer component.

[0003] The integration of manufactured components into existing structures plays a crucial role in construction and medical technology, among other areas. For implants or bone replacement materials, good and rapid integration into the body's own tissue structures is particularly essential. The better the structural properties of a bone's tissue structure, for example, can be replicated, the better the "artificial" implant will integrate. Vascularization structures, in particular, play a crucial role in ensuring good ingrowth into bone tissue. These special, highly branched, vertically and horizontally positioned channels (Haversian and Volkmann canals) ensure that the bone tissue is supplied with blood and nutrients on all sides, allowing natural tissue remodeling and degradation processes to occur.These structures are very small-scale and range in size from 20 pm - 40 pm or 70 pm - 200 pm.

[0004] To date, no technical solution exists to artificially create the above-mentioned complex and branched structures from bone-like materials (with calcium phosphate components) and thus to produce implants that enable ingrowth and thus bone modeling, bone remodeling, bone restoration, or bone regeneration. There are already known studies attempting to realize similarly fine structures as the vascularization structures using bone-like materials. These primarily draw on biological models. Among other things, it is shown how nanoscale hydroxyapatite (i.e., a calcium phosphate) can be produced in natural collagen fibril structures (micrometer-sized, evenly arranged vertical channel structures) through chemical reactions. This is done, for example,by infiltrating such fibril structures in a calcium solution with hydrogen phosphate to create a material hybrid of collagen and hydroxyapatite. It is also possible to use natural plant and wood structures (e.g., rattan) as a starting structure and then convert the natural fiber-formed structure into calcium phosphate (here, also hydroxyapatite) through highly energy-intensive subsequent processes. For this, the rattan structure must first be pyrolyzed at 1000°C to transform it into a carbon construct. This is then converted to CaC2 through a calcium vapor process, subsequently oxidized to CaO (and releasing CO2), then carbonated to CaCO3, and finally transformed to hydroxyapatite by phosphatization with potassium phosphate. Here, too, only uniform, vertical channel structures are present. This means that, at best, only one-dimensional fluid transport can occur.In addition, the process is very energy-intensive and therefore costly.

[0005] To avoid these disadvantages, DE 10 055 465 A1 discloses a method for producing a bone replacement implant consisting of a matrix of a polymer material with embedded filler particles made of an inorganic, non-metallic material. The implant is built up layer by layer using laser sintering from a powdered mixture consisting of the matrix polymer and the filler particles. A disadvantage of this method is that the filler concentration must be determined at the beginning of the process and cannot be subsequently changed. Thus, the implant properties, which are largely determined by the filler concentration, cannot be flexibly adapted to the respective application. This limits the individual integration capabilities of the component.

[0006] The present invention is therefore based on the object of proposing a method for producing a component and a component itself which has an improved ability to be integrated into existing material structures.

[0007] This object is achieved according to the invention by a method for producing a mineralized polymer component according to claim 1 and by a mineralized polymer component according to claim 6. Advantageous embodiments and further developments are described in the dependent claims.

[0008] In a method for producing a mineralized polymer component, a support structure made of a polymer-based material is formed starting from an image data set, wherein the support structure has at least a first region in which the polymer-based material is formed and at least a second region which is designed as a hollow structure. Subsequently, at least one inorganic mineral phase is formed on the surface of the support structure and / or within the first region and / or on at least one inner surface of the first region. The image data set provides a high-resolution image of the support structure to be produced, which is either recorded at the start of the process or is already available at the start of the process. In this case, structures in the nanometer range can be resolved, which means that even complex natural structures can be digitally reproduced, i.e. recorded, as an image data set.complex artificial structures can be generated. This high-resolution image dataset makes it possible to produce an equally high-resolution support structure. This allows the geometries and dimensions found in reality, particularly those of various physiological bones, to be mapped. This means that the bone can not only be reproduced physiologically accurately in terms of its external appearance (geometry and shape) using the support structure, but the Haversian and Volkmann canals that run through the real bone can also be reproduced. As a result, the support structure has almost identical geometric properties to the respective bone for which an implant or bone replacement material is to be provided.

[0009] By depositing at least one inorganic mineral phase, the similarity to the existing structure to be replicated or replaced can be further improved. Among other things, the inorganic mineral phase improves the possibility of integration into the existing structure. This is advantageous for implants, bone implants, or bone replacement materials, for example, because the formation of a bone-like inorganic mineral phase can significantly improve biointegration into the surrounding tissue.

[0010] Another advantage is that the targeted formation of the mineral phase at different locations on the support structure can further improve the similarity to the structure to be replicated or replaced.

[0011] This means that through targeted formation of the mineral phase, for example on the inner surface of the first region, the ideal properties for the respective application can be achieved. In addition, the formation “within” the first region means that the mineral phase is completely enclosed by the polymer-based material. This can also mean that the mineral phase can completely fill the polymer-based material. The formation of the mineral phase “on the surface of the support structure” or “on the inner surface of the first region” is to be understood such that the mineral phase at least partially covers the surface. In this case, a mineral phase that covers part of the surface can also extend into the first region. This means that the mineral phase is partially on the inner surface of the first region oron the surface of the support structure and partially within the first region.

[0012] In addition, it can be provided that the inorganic mineral phase is formed by the support structure first being surrounded by at least one first fluid which comprises at least one first element of the mineral phase and then by at least one second fluid which comprises at least one second element of the mineral phase and / or by at least one second region being flooded.

[0013] First, within this application, "element" refers to chemical elements. "Surrounded" means that at least one surface is in contact with the fluids. Particularly preferred is the state in which the support structure is completely surrounded by the fluids. This means that the fluid is formed around the support structure on all sides. The flow through the second region refers to both the first fluid and the second fluid. This means that both the first fluid and subsequently the second fluid come into contact with the outer surface of the support structure as well as with the inner surfaces of the first region, which are formed by the formation of the second region.This has the advantage that initially the at least one first element of the respective mineral phase and subsequently the at least one second element of the respective mineral phase accumulates at the described locations on the support structure, and the inorganic mineral phase is formed by the mineralization reaction that then takes place, including with the participation of the enriched elements. In particular, the mineral phase can thus be formed within the first region as well as on the inner surface of the first region. In this case, liquid fluids can be used particularly advantageously as the first and / or second fluid to introduce the elements into the second region, such that the elements can be transported into the first region both via the surface of the support structure and via the inner surface of the first region.In addition, these fluids exhibit particularly good wettability for the polymer material used to form the support structure. Gaseous fluids can also be used as an alternative to liquid fluids.

[0014] Another advantage of this design is that the concentration of the inorganic mineral phase can be determined by the reaction conditions, which can be influenced and changed, i.e. for example by the reaction duration, the composition of the elements and the concentration of the respective elements. Provided that sufficient reactants are present, a longer reaction duration, for example, means an increase in the concentration of the formed mineral phase. Furthermore, the ratio of the times in which the support structure is in contact with the first fluid and with the second fluid plays a decisive role in relation to the degree of mineralization. Basically, the formation of the inorganic mineral phase is determined or limited by the concentrations of the respective elements that are necessary to form the inorganic mineral phase.This means that the mineralization reaction can only take place as long as there are enough reaction partners, i.e. at least the first elements and the second elements, present.

[0015] Alternatively, the inorganic mineral phase can be formed by doping the polymer-based material with at least a first element of the inorganic mineral phase before the formation of the support structure and then surrounding the support structure, preferably the doped support structure, with a second fluid which has at least a second element of the mineral phase and / or flooding at least a second region.

[0016] The advantage of pre-doping the polymer-based material is that a defined dopant concentration can be determined in advance. This makes it possible to precisely determine the concentration of the mineral phase by adjusting the concentration of a first element. The reaction of the first element with the second element to form the inorganic mineral phase is determined or limited by the dopant concentration of the first element.

[0017] In addition, the image data set can be acquired using imaging techniques, in particular digital volume tomography (DVT) and / or generated using computer-aided design methods.

[0018] In principle, the image dataset can include both two-dimensional and three-dimensional image data. Volumetric image datasets should be available, in particular. Using, for example, DVT, the resolution quality can be further increased, allowing the structure to be reproduced to be digitally imaged quickly and easily. Alternatively, it can also be provided that structures can be generated or constructed using computer-aided design methods. This means, in particular, CAD models (computer-aided design) that can include two-dimensional or three-dimensional images. This allows support structures to be designed that are tailored to the respective application task.

[0019] In addition, the support structure can be manufactured by means of an additive manufacturing process, in particular by means of three-dimensional volumetric printing (3DVP) or a gelling process or a casting process.

[0020] The use of additive manufacturing processes offers the advantage of being able to produce flexible support structures tailored to the specific application in a very short time. This increases the flexibility of the process and expands the potential areas of application.

[0021] A component with a mineralized polymer structure comprises a support structure formed from a polymer-based material based on an image data set, wherein the support structure has at least one first region in which the polymer-based material is formed and at least one second region formed as a hollow structure. Furthermore, at least one inorganic mineral phase is formed on the surface of the support structure and / or within the first region and / or on at least one inner surface of the first region.

[0022] These components make it possible to improve their integration into their environment, e.g., the organism, thanks to the realistically simulated structures into which the component is to be integrated. Furthermore, the selected material combination—that is, the combination of polymer material and mineral phase—can address a wide variety of application areas.

[0023] Furthermore, the inorganic mineral phase can comprise minerals of the mineral class of oxides and hydroxides, in particular ZrO2 and Al2O3, and / or carbonates, in particular CaCO3, and / or phosphates, in particular Ca3(PO4)2, CaHPO4 and Cas(OH)(PO4)3.

[0024] This variety of possible mineral phases further expands the application range of the components. For example, the formation of calcium phosphate (Ca3(PO4)2), calcium hydrogen phosphate (CaHPO4), and hydroxyapatite (Cas(OH)(PO4)3) is particularly suitable for use in medical technology, such as the reconstruction of bones or bone replacement materials. The use of zirconium oxide (ZrO2) and aluminum oxide (Al2O3), on the other hand, is particularly relevant for use as technical ceramics in aerospace, automotive, and similar areas.

[0025] In addition, the support structure can be formed from a hydrogel, in particular from gelatin, agar, alginate or a structural protein, in particular collagen, or from biopolymers such as polycaprolactone (PCL) or polylactic acid (PLA) and / or the support structure can comprise active ingredients, in particular antibiotics and / or bacteria, in particular cyanobacteria and / or plant cells and / or fungal cells and / or animal cells and / or human cells.

[0026] By forming the support structure from the materials listed above, the potential for integration into the environment, for example, biointegration into organisms, is significantly increased, allowing the mineralized polymer component to be introduced into the body easily and with minimal rejection reactions. Rejection reactions can also be reduced by the additives described. The aforementioned components can be added prior to the structuring methods mentioned, and thus before mineralization and / or after structuring and / or during mineralization and / or after mineralization.

[0027] In addition, the second region can be formed from branched channels with diameters in a range from 10 nm to 10 cm, preferably in a range from 1 pm to 1 mm, particularly preferably in a range from 20 pm to 200 pm. Furthermore, the degree of mineralization can be in a range from 10 vol% to 80 vol%, preferably in a range from 20 vol% to 60 vol%, particularly preferably in a range from 30 vol% to 50 vol%.

[0028] First, "branched" means that the channels run in all spatial directions and can be connected to each other in any way, creating a network of channels. Alternatively, the second region can also be formed from a combination of different hollow structures. This allows highly complex and detailed structures to be reproduced, further increasing the degree of similarity between the component and the structure into which it is to be integrated. Furthermore, the wide variability of the mineral phase concentration ranges expands the possible areas of application of the component.

[0029] The component can be manufactured using the described method, ie the method is suitable for manufacturing the described component.

[0030] Embodiments of the invention are illustrated in the drawings and are described below with reference to Figures 1 to 4. Recurring features are provided with identical reference numerals.

[0031] Shown are: Fig. 1 a schematic drawing of a support structure with branched channels;

[0032] Fig. 2 is a schematic internal view of a section of a support structure with branched channels;

[0033] Fig. 3 is a schematic representation of a first embodiment of the method for producing a component with mineralized polymer structures and

[0034] Fig. 4 is a schematic drawing of a second embodiment of the method for producing a component with mineralized polymer structures.

[0035] Fig. 1 shows a support structure 1 of a mineralized polymer component, wherein the support structure 1 is formed from a polymer-based material. The support structure 1 has a first region 5, in which the polymer-based material is formed, and a second region 2. In this embodiment, the second region 2 is formed from branched channels with different diameters and geometries. In addition, the support structure 1 has four openings, which represent the inlets and outlets of some branched channels, which thus form a hollow structure or a cavity within the first region 5. This means that no polymer-based material is formed in the branched channels, i.e. the hollow structures, i.e. in the second region 2.Since the hollow structure is formed within the first region, the first region 5 delimits the hollow structure, so that an inner surface of the first region 5 is understood as the surface that forms the transition between the first region 5 and the second region 2. Not shown in this embodiment is that the openings of the channels can also be located on other surfaces of the support structure 1. This means that the channels can form a highly branched network within the support structure 1, so that the channels can run in all spatial directions.

[0036] The branched channels are shown again in Fig. 2 within the support structure 1. Here, a section A of the support structure 1 from Fig. 1 shows an interior view of the support structure 1, so that a multitude of branches between the various channels can be seen. These connections or branches can also run in any spatial direction and can connect one or more channels to one another. The connections between the channels are themselves also understood as channels, so that one speaks of a channel network. Furthermore, in addition to such a channel network, further regions 2 can also be designed as hollow structures, for example, also emerging horizontally to the support structure 1. The further regions 2 can be connected to the existing channel network, but can also have no connection to the channel network. This enables the formation of complex hollow structures within the first region 5.

[0037] In this exemplary embodiment, the support structure 1 is manufactured using three-dimensional volumetric printing (3DVP) based on a previously acquired image dataset in order to be used as a bone replacement material. By forming the channels within the support structure 1, the physiological bone can be artificially recreated. The network of channels within the support structure 1 replicates the channel structure of the physiological bone formed from the so-called Haversian and Volkmann canals (vascularization structures), which is crucial for supplying the bone with nutrients. By artificially reproducing this network of channels in the support structure 1, the biointegration capacity of the support structure 1 is increased after installation in the respective bone. At least the structural-mechanical properties of the support structure 1 are thus adapted to the respective bone tissue (e.g., the course of load trajectories).

[0038] As already mentioned, the support structure 1 is formed based on an image dataset. This image dataset can be acquired, for example, using digital volume tomography (DVT). Particularly in the medical field, it is advantageous for this image dataset to be acquired for each application, i.e., for each patient, thus patient-specific and individually. Since the properties of the bone and the geometry differ from person to person, an individual replica of the respective bone based on an individual image dataset offers considerable advantages with regard to the individual biointegration of the respective support structure 1 into the respective bone.

[0039] Fig. 3 now schematically represents a possible process sequence for producing a component with mineralized polymer structures. As already described, a volumetric 3D printing process (3DVP) is used here, which allows the production of high-resolution vascularization structures on the basis of recorded patient-specific data (e.g. DVT) of a bone. Alternatively, the image data set can be generated using other imaging processes or by means of computer-aided design processes, i.e. computer-generated two-dimensional or three-dimensional images of artificial or abstract geometries. The support structure 1 can also be produced using another additive manufacturing process or a gelling process or a casting process. The material from which the support structure 1 is formed is a (bio)polymer based on gelatin: this so-calledGel-MA (gelatin methacrylate) can be a porcine gelatin functionalized with methacrylate, making it suitable for light-curing additive manufacturing. Alternatively, any other polymer suitable for processing using light-curing additive manufacturing can be used.

[0040] In addition, the polymeric base material forming the support structure 1 can be used with photoinitiators [such as phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide (BAPO or Igracure 819), 2,2-dimethoxy-2-phenylacetophenone (DMPA or Igracure 651), lithium phenyl(2,4,6-trimethylbenzoyl)phosphinate (LAP) and diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide (TPO)] and / or monomers for light-curing and additive / generative / volumetric manufacturing processes. For example, methacrylic anhydride (MA) can be used as a monomer, which together with gelatin forms a methacryloyl-modified gelatin (GelMA) and thus a popular (photo)chemically cross-linked, protein-based hydrogel-based biopolymer. In the now generated three-dimensional After three-dimensional volumetric production in situ, a nanometer-scale (bio)mineralization to calcium phosphate - e.g. hydroxylapatite - takes place in the (bio)polymer structure (support structure 1).For this purpose, after printing, the support structure 1 is placed in a tank containing a first fluid 3, in this case a calcium chloride solution (CaCl2), for 12 hours, then removed and finally placed in a tank containing a second fluid 4, in this case a disodium hydrogen phosphate solution (Na2HPO4), for 12 hours. This means that the actual mineralization reaction starts as soon as the support structure 1 has been placed in the second fluid 4 and ends as soon as one of the reactants has been completely used up. Alternatively, the support structure 1 can also be placed first in the second fluid 4 and then in the first fluid 3. In this case, the support structure 1 is surrounded by the fluids so that the channels are also completely flooded. As a result, hydroxyapatite forms, among other things, in the channels as an inorganic material phase. This can be described by the following two-stage reaction equation.

[0041] This reaction occurs particularly at a pH value in the range of 9-10, whereby the reaction time can last from a few minutes to a few days, depending on the desired degree of mineralization of the support structure 1. In principle, the degree of mineralization can be up to 80 vol.%. Preferably in a range of 20 vol.% to 60 vol.%, particularly preferably in a range of 30 vol.% to 50 vol.%. With regard to the degree of mineralization, i.e. the desired mineral concentration within the support structure 1, the following reaction conditions are also crucial: first, the polymer concentration within the support structure 1, and later, the amount of mineral to be formed. The higher the polymer concentration at the beginning of material production, the lower the degree of mineralization at the end.

[0042] Since the starting material can be a polymer solution, the base fluid for doping the material with a mineral phase element is crucial in this case. Depending on the choice, this influences the degree of mineralization. The ion concentration within fluids 3 and 4 also has a decisive effect on mineral synthesis. Generally speaking, the higher the concentration, the greater the degree of mineralization. However, this only applies up to the point at which saturation occurs and the excess ions no longer form a mineral within the support structure 1. Therefore, the ratio of the ion concentrations within the fluids 3 and 4 used to each other is also relevant.

[0043] The length of time the support structure 1 is immersed in the respective solution also affects the degree of mineralization. However, this only has a limited effect, since at a certain point, ion saturation occurs within the support structure, so that mineral formation continues, but ion exchange with the fluid 3, 4 no longer takes place. Furthermore, the choice of the hydrogel-based (bio)polymer material influences the degree of mineralization. Of particular note here are the interactions with the aforementioned reaction conditions.

[0044] The formation of hydroxyapatite makes it possible to further increase the similarity between bone tissue and the component, as hydroxyapatite is a major component of physiological bone. This further improves the biointegration capacity of the component with mineralized polymer structures. The concentration of the mineral phase depends on the duration of the incorporation process, the available elements, and the flow conditions. To achieve ideal biointegration—i.e., to achieve the most bone-like properties of the component possible—the concentration ideally ranges from 30 vol.% to 50 vol.%.

[0045] Alternatively, the channel network can also be flooded without inserting the support structure into the fluids. In this case, the fluids can be introduced separately into the channel network. It is also possible to flood only part of the channel network with the fluids, so that, for example, only one channel comes into contact with the fluids. In addition, it is also possible for the first fluid 3 and / or the second fluid 4 to surround the support structure 1 dynamically, rather than statically. This means that the fluids can have a flow and thus flow around the support structure 1 and flow through the channels. In addition, it can also be provided that additional fluids are provided which surround the support structure 1 after the first fluid 3 and after the second fluid 4. An alternating, i.e. repeated introduction of the support structure 1 into the first fluid and then into the second fluid can also be provided.

[0046] This variety of fluid introduction options allows the formation of the mineral phase in the support structure to occur selectively in specific areas. For example, it is possible to achieve increased enrichment of the mineral phase in a portion of the channel network. This offers the possibility of mineralizing the support structure 1 such that the mineral concentration resembles that in the tissue to be integrated (e.g., bone). This ensures that the support structure 1 is optimally adapted to the topology and composition of the existing tissue. This means that the mineral phase concentration does not have to be evenly distributed throughout the volume of the support structure 1.

[0047] Fig. 4, in contrast, shows a further process variant, the difference being that the polymer-based material is additionally doped with an element of the later mineral phase. Here, Gel-MA is again used as the polymer material, which is dissolved in NazHPC, so that a doped complex structure 1a is produced by 3D printing. The complex structure 1a is then placed in a second fluid 4 for 24 hours, here a solution with calcium ions such as calcium chloride, analogous to the process in Fig. 3. This initiates the mineralization reaction; the calcium ions now migrate into the (bio)polymer matrix material and form calcium phosphate in the form of hydroxyapatite.

[0048] Thus, the mineralization of support structure 1 or the doped support structure 1a is based on ion and electron migration as well as diffusion processes. The result in both cases, like a real bone in its formation, is a polymer-mineral composite with bone-like properties, which possesses mimicked highly branched vascular structures. Such a component can therefore be used as an inorganic-organic composite material without heat treatment or, alternatively, after sintering, as a novel bioceramic bone imitation.

[0049] Analogously, the channel network can also be flooded without inserting the doped support structure 1a into the second fluid 4. In this case, the second fluid 4 can be introduced separately into the channel network. Furthermore, it is possible to flood only part of the channel network with the second fluid 4, so that, for example, only one channel comes into contact with the second fluid 4. In addition, it is also possible for the second fluid 4 to surround the doped support structure 1a dynamically rather than statically. This means that the fluid 4 can have a flow and thus flow around the doped support structure 1a and flow through the channels. Furthermore, it can also be provided that additional fluids are provided which surround the doped support structure 1a after the second fluid 4. An alternating, i.e. repeated, introduction of the doped support structure 1a into different fluids can also be provided.

[0050] Other gelatins, e.g., those derived from beef or fish, can also be used as organic support structures 1. Biodegradable biopolymers such as PCL (polycaprolactone) and PLA (polylactic acid), as well as collagen or other hydrogels, can also be used. The hydrogels can also be functionalized in other ways. When used with the 3DVP shown here, only light-curing polymerization of the material must be possible. Furthermore, the (bio)polymer material can be manufactured using a variety of other additive manufacturing methods, such as 2-photon polymerization, fused filament fabrication, bioplotting, or stereolithography.

[0051] Alternatively, the support structure 1 can also be produced via gelation and casting processes. The mineralization process can also subsequently take place in these processes. The in-situ production of the inorganic mineral phases themselves can include mineralization syntheses such as those described for calcium phosphates (hydroxyapatite, tricalcium phosphate, etc.), calcium carbonates, but also other mineralization syntheses such as materials based on ZrO2 or Al2O3. Other similar oxidic and non-oxidic inorganic materials can also be synthesized in this way, in which molecular bonds are generated via appropriate electron / ion movement.

[0052] The most important advantage here is that mineral components can be enriched in technologically and industrially manufactured, structurally highly complex, small-scale, and delicate support structures 1 , thus allowing, for example, the aforementioned vascularization structures of natural bone to be imitated in an artificial bone structure. This, in turn, should enable improved ingrowth of the construct and improved bone regeneration capacity in the human organism, thus enabling rapid patient rehabilitation.

[0053] In addition, the mechanical properties of support structure 1 can be achieved through a higher mineral content. This can be adjusted by the mineralization time or the ion concentration. This higher mineral content ensures that, for example, a correspondingly rigid structure is present after sintering. In conjunction with the topologically optimized geometric replicas of the real bone, comparable mechanical properties could be achieved in the artificial bone. Alternatively, the mechanical properties can also be adjusted without sintering. In this case, the structural composition of the real bone can be remodeled in the polymer-based and powder-filled state of the component. The underlying stiffness can be influenced and controlled via the mineral content (be it through mineralization time or chemical ratios).Alternatively, the mechanical properties can be influenced by drying processes, but also by the choice of the material itself, which represents the polymer base.

[0054] In particular, through geometric construction or DVT scans, a bone-cartilage transition can be created within a composite structure. For this purpose, one section of a model can be constructed in such a way that trabecular or spongy bone structures are present, while the other section remains as a polymer. In this case, only the spongy structure is mineralized. This allows the creation of an artificial bone-cartilage implant. Additional active ingredients (e.g. antibiotics), bacteria (e.g. cyanobacteria), plant cells or fungal cells, or animal or human cells can be added either via the aforementioned 3D printing (additive processes) or casting or gelling processes during these structuring methods and thus before mineralization, or after structuring and during mineralization, or after mineralization.

[0055] The main application area is the development and production of bone replacement materials and implant structures. When calcium carbonates are manufactured in polymer constructs, the construction sector is also a potential target.

[0056] Technical ceramics can also be produced through mineralization in filigree complex polymer structures with other inorganic materials, e.g. based on ZrCh, AlzCh and similar oxide and non-oxide bases.

Claims

Patent claims 1. A method for producing a mineralized polymer component, in which a support structure (1) is formed from a polymer-based material starting from an image data set, wherein the support structure (1) has at least a first region (5) in which the polymer-based material is formed, and at least one second region (2) which is formed as a hollow structure, and then at least one inorganic mineral phase is formed on the surface of the support structure (1) and / or within the first region (5) and / or on at least one inner surface of the first region (5).

2. A method for producing a mineralized polymer component according to claim 1, characterized in that the inorganic mineral phase is formed by first surrounding the support structure (1) by at least one first fluid (3) comprising at least one first element of the mineral phase and then by at least one second fluid (4) comprising at least one second element of the mineral phase and / or by flooding at least one second region (2).

3. A method for producing a mineralized polymer component according to claim 1, characterized in that the inorganic mineral phase is formed by doping the polymer-based material with a first element of the inorganic mineral phase before forming the support structure (1) and then doping the support structure (1) with a second fluid (4) which contains at least a second element element of the mineral phase, and / or at least a second area (2) is flooded.

4. A method for producing a mineralized polymer component according to one of the preceding claims, characterized in that the image data set is recorded by means of imaging methods, in particular by means of digital volume tomography (DVT) and / or is generated by means of computer-aided design methods.

5. A method for producing a mineralized polymer component according to one of the preceding claims, characterized in that the support structure (1) is produced by means of an additive manufacturing method, in particular by means of three-dimensional volumetric printing (3DVP) or a gelling method or a casting method.

6. Mineralized polymer component comprising: a support structure (1) which is formed from a polymer-based material on the basis of an image data set, wherein the support structure (1) has at least a first region (5) in which the polymer-based material is formed and at least one second region (2) which is formed as a hollow structure, and at least one inorganic mineral phase is formed on the surface of the support structure (1) and / or within the first region (5) and / or on an inner surface of the first region (5).

7. Mineralized polymer component according to claim 6, characterized in that the inorganic mineral phase comprises the minerals of the mineral class of oxides and hydroxides, in particular ZrO2 and Al2O3, and / or carbonates, in particular CaCO3, and / or phosphates, in particular Ca3(PO4)2, CaHPO4 and Ca(OH)(PO4)3.

8. Mineralized polymer component according to one of claims 6 and 7, characterized in that the support structure (1) is formed from a hydrogel, in particular from gelatin, agar, alginate or a structural protein, in particular collagen, or from biopolymers such as polycaprolactone (PCL) or polylactic acid (PLA) and / or the support structure (1) comprises active ingredients, in particular antibiotics and / or bacteria, in particular cyanobacteria and / or plant cells and / or fungal cells and / or animal cells and / or human cells.

9. Mineralized polymer component according to one of claims 6 to 8, characterized in that the second region (2) consists of branched Channels with diameters in a range of 10 nm to 10 cm, preferably in a range of 1 pm to 1 mm, particularly preferably in a range of 20 pm to 200 pm.

10. Mineralized polymer component according to claim 6 to 9, characterized in that the degree of mineralization is in a range of 10 Vol.% to 80 Vol.%, preferably in a range of 20 Vol.% to 60 Vol.%, particularly preferably in a range of 30 Vol.% to 50 Vol.%.

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