Artificial Bone Structure With Dense-Porous Ceramic Zoning

Solution Overview

Problem

Three-dimensional shaped objects made of ceramic materials face challenges in achieving both high strength and compatibility with living bone, as high density hinders bone fusion while low density compromises structural integrity.

Innovation Solution

A three-dimensional shaped object is manufactured with a dense portion and a porous portion formed by a reaction product of a ceramic material with a chelating agent, where the dense portion has a higher application of a curing liquid than the porous portion, allowing for both high strength and compatibility with living bone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the internal dense degree of the artificial bone is increased to secure strength, then the strength is improved, but the growth of new bone is hindered, resulting in delayed fusion with living bone

Engineering Contradiction:

Improvestrength of artificial boneVSAvoidfusibility and replaceability with living bone

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The artificial bone is designed with spatially varying density: a dense portion (first region) providing structural strength and a porous portion (second region) facilitating bone ingrowth. This local differentiation resolves the contradiction by assigning different density characteristics to different functional zones within the same structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The artificial bone combines two distinct material structures (dense ceramic material and porous ceramic material) into a single composite structure. The dense portion provides mechanical strength while the porous portion enables biological integration, achieving both requirements simultaneously through material composition rather than uniform structure.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If the internal dense degree is decreased to promote bone growth, then the fusibility with living bone is improved, but the strength becomes insufficient for reinforcing the living bone

Engineering Contradiction:

Improvefusibility and replaceability with living boneVSAvoidstrength of artificial bone

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The artificial bone is designed with spatially varying density: a dense portion (first region) providing structural strength and a porous portion (second region) facilitating bone ingrowth. This local differentiation resolves the contradiction by assigning different density characteristics to different functional zones within the same structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The artificial bone combines two distinct material structures (dense ceramic material and porous ceramic material) into a single composite structure. The dense portion provides mechanical strength while the porous portion enables biological integration, achieving both requirements simultaneously through material composition rather than uniform structure.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If a uniform dense structure is used throughout the artificial bone, then the manufacturing process is simplified, but the artificial bone cannot achieve both high strength and bone fusion capability

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoiddual property achievement (strength and bone fusion)

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The artificial bone is designed with spatially varying density: a dense portion (first region) providing structural strength and a porous portion (second region) facilitating bone ingrowth. This local differentiation resolves the contradiction by assigning different density characteristics to different functional zones within the same structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The artificial bone is divided into two distinct regions (first region and second region) with different density characteristics. This segmentation allows each region to fulfill its specific function while being manufactured as an integrated structure through controlled application of curing liquid in different amounts.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The object achieves high strength through its dense portion and facilitates bone fusion and replacement with a living bone due to its porous portion, enhancing both structural integrity and biological integration.

Implementation Method 1

a dense portion and a porous portion which are formed by a reaction product of a ceramic material with a chelating agent

Methodology Applied

Scientific EffectChemical reaction between ceramic material and chelating agent: Chemical Bonding

Data Source

PatentEP4226955B1Artificial bone, method for manufacturing three-dimensional shaped object, and control program

Publication Date: 2026.02.11 RIKEN CO LTD

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AI summary

A three-dimensional shaped object can achieve both of a property in the case of a high dense degree and a property in the case of a low dense degree, and have a high strength. The three-dimensional shaped object (10) includes a dense portion (3) formed on one side so as to be dense, and a porous portion (5) formed on an opposite side so as to be porous. The dense portion (3) and the porous portion (5) are formed by a reaction product of a ceramic material with a chelating agent.