3D-Printed Synthetic Bone Grafts With Interlocked CDHA Matrix

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Solution Overview

Problem

Existing bone graft substitutes face limitations such as ceramic particles acting as fillers, high sintering temperatures leading to decomposition of the polymeric phase, shrinkage, brittleness, and reduced biological performance, as well as issues with natural materials like collagen, alginate, and chitosan regarding reproducibility, degradation rate, mechanical properties, and disease transmission.

Innovation Solution

A composite scaffold design with a continuous ceramic phase based on interlocked CDHA crystals and a continuous polymeric phase, achieved through a method involving 3D-printing followed by two hardening steps: first hardening the binder and then the ceramic particles, resulting in a scaffold with enhanced mechanical and biological properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If sintering process is used to fabricate ceramic scaffolds, then mechanical strength is improved, but polymeric phase decomposes and biological performance is reduced

Engineering Contradiction:

Improvemechanical strengthVSAvoidbiological performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the processing parameters by replacing high-temperature sintering with low-temperature drying (below 100°C) to preserve the polymeric phase while achieving sufficient mechanical strength through a different mechanism (interlocked crystal structure rather than sintering bonds)

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining ceramic particles (CaP-based) with a polymeric binder phase, where the polymeric phase serves as both binder and functional component, achieving both mechanical strength and biological performance through material composition rather than processing temperature

Inventive Principle:

Principle #40Composite materials

2Strength

If high sintering temperature is applied to ceramic particles, then mechanical strength is improved, but shrinkage and brittleness occur

Engineering Contradiction:

Improvemechanical strengthVSAvoiddimensional stability

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent changes the temperature parameter from high-temperature sintering (>900°C) to low-temperature drying (<100°C), eliminating thermal shrinkage and brittleness while achieving mechanical strength through alternative mechanisms (interlocked crystal structure and polymeric binding)

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If ceramic particles are embedded in binder matrix, then scaffold structure is formed, but ceramic particles only act as fillers with limited bioactivity

Engineering Contradiction:

Improvescaffold structure formationVSAvoidbioactive performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent creates a composite where ceramic particles are not merely fillers but form an interlocked crystal structure that provides both mechanical framework and bioactive surface area, while the polymeric phase provides binding and biological functionality, achieving synergistic enhancement of both structural and bioactive properties

Inventive Principle:

Principle #40Composite materials

4Reliability

If natural materials (collagen, alginate, chitosan) are used for bone grafts, then biocompatibility is improved, but reproducibility and degradation rate control become difficult

Engineering Contradiction:

ImprovebiocompatibilityVSAvoidreproducibility

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent uses synthetic polymeric materials (e.g., PLGA, PCL, PEG) as binders that provide controlled degradation rates and consistent mechanical properties, combining them with bioactive ceramic particles to achieve both reproducibility and biocompatibility through predictable material behavior

Inventive Principle:

Principle #40Composite materials

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 scaffold exhibits increased flexural toughness and compressive strength, improved fixability, and excellent biological properties in vitro, mimicking native bone structure and function.

Implementation Method 1

one or more water-soluble photo-crosslinkable binder(s)... crosslinking the one or more photo-crosslinkable binder(s)

Methodology Applied

Scientific EffectPhoto-crosslinking: Photopolymerisation

Implementation Method 2

The transformation of the ceramic particles is based on the hydrolysis of the α-TCP

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 3

the ceramic particles are transformed into calcium-deficient hydroxyapatite (CDHA) crystals

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentUS20260069746A1Synthetic bone grafts and methods for their preparation

Publication Date: 2026.03.12 NOBEL BIOCARE SERVICES AG

AI summary

The present invention provides methods for the preparation of synthetic bone grafts which are made of a composition comprising two matrixes, one ceramic including interlocked CDHA crystals, and another of one or more binder(s), the two matrixes being admixture. The method comprises the preparing of an ink composition, the 3D-printing, and the hardening of the binder and ceramic components, in this order.The resulting bone grafts, which are characterized by including the two matrixes in admixture, shows improved mechanical properties as well as excellent biological properties.