3D Printed Bone Scaffold with Microporous Shell
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Solution Overview
Problem
Current bone repair technologies, such as autogenous tissue grafts and alloplastic materials, face challenges in custom-fabrication for complex defects, inconsistent performance, and inadequate resorption, leading to suboptimal bone regeneration and prolonged healing times.
Innovation Solution
A multiphasic, three-dimensionally printed tissue repair device with a porous bone ingrowth area and a microporous shell, featuring interconnected struts and varying mesopore sizes, which can be infiltrated with soluble fillers and bioactive agents, allowing for custom-fabrication and promoting bone growth across complex defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional bone grafting materials (autogenous, allograft, or alloplastic) are used, then bone defect filling is achieved, but custom-fabrication for complex defects is limited and healing time is prolonged
Solution Approach 1:
The patent applies parameter changes by varying pore size, porosity, and material composition across different regions of the scaffold to optimize both custom-fabrication capability and healing time. The 3D printing process allows precise control of these parameters to match specific defect geometries while promoting accelerated bone regeneration.
Solution Approach 2:
The patent uses composite materials combining multiple bone graft substitutes (e.g., hydroxyapatite, beta-tricalcium phosphate, calcium sulfate) within a single custom-fabricated scaffold. This allows optimization of both manufacturing precision for complex defects and biological performance for accelerated healing.
2Stability of the object's composition
If alloplastic materials are used for bone repair, then material availability and consistency are improved, but resorption is inadequate and infection risk increases
Solution Approach 1:
The patent applies local quality by creating spatially varying material compositions within the scaffold, with different regions containing different ratios of resorbable and non-resorbable materials. This allows the scaffold to maintain structural stability where needed while providing adequate resorption in regions requiring bone regeneration.
Solution Approach 2:
The patent changes material parameters by incorporating resorbable components (such as calcium sulfate and beta-tricalcium phosphate) alongside non-resorbable hydroxyapatite, enabling controlled resorption while maintaining material consistency and reliability throughout the scaffold structure.
3Quantity of substance
If three dimensional foam scaffold fabrication techniques are used, then overall pore size distribution is controlled, but individual pore location, morphology, and interconnectivity are not controlled
Solution Approach 1:
The patent applies local quality by enabling spatial variation in pore characteristics throughout the scaffold structure. The 3D printing process allows different regions to have customized pore sizes, shapes, and interconnectivity patterns optimized for specific biological functions such as nutrient transport, cell migration, and vascularization.
Solution Approach 2:
The patent transitions from two-dimensional pore control to three-dimensional pore architecture control. The 3D printing process enables precise control of pore location, morphology, and interconnectivity in all three spatial dimensions, allowing optimization of nutrient and metabolite exchange pathways throughout the entire scaffold volume.
4Manufacturing precision
If direct write three dimensional printing is used, then high resolution and reproducibility are achieved, but processing complexity and temperature requirements increase
Solution Approach 1:
The patent applies segmentation by dividing the complex processing into distinct stages: printing the green body scaffold structure, then separately performing binder burnout and sintering. This segmentation allows optimization of each stage independently, maintaining high resolution while managing processing complexity through systematic breakdown of steps.
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 device enables efficient bone regeneration, reducing healing times by up to 90% and allowing for the growth of both cortical and trabecular bone, with customizable pore structures to match specific bone defects, facilitating faster and more effective bone repair.
Implementation Method 1
a useful three dimensional printing process, direct write (DW)... The scaffolds are printed by ink extrusion on the XY plane... Post-processing of the printed green bodies requires binder burnout and sintering
Implementation Method 2
The porous ingrowth structure may be infiltrated with a soluble filler or carrier, such as, for example calcium sulfate. This soluble filler or carrier, such as, for example calcium sulfate, may be infiltrated with one or more of an antibiotic, a growth factor, a differentiation factor, a cytokine, a drug, or a combination of these agents.
Implementation Method 3
A useful three dimensional printing process, direct write (DW), as detailed by Nadkarni et al., J Am Ceram Soc 2006; 89:96-103 is based on the extrusion/deposition of colloidal inks as continuous filaments.
Data Source
AI summary
The present invention relates to multiphasic, three-dimensionally printed, tissue repair devices or scaffolds useful for promoting bone growth and treating bone fracture, defect or deficiency, methods for making the same and methods for promoting bone growth and treating bone fracture, defect or deficiency using the same. The scaffold has a porous bone ingrowth area containing interconnected struts surrounded by a microporous shell. At the ends of the scaffold, the shell may be extended as a guide flange to stabilize the scaffold between ends of bone. The center of the scaffold may be empty and may serve as a potential marrow space. The porous ingrowth structure may be infiltrated with a soluble filler or carrier, such as, for example calcium sulfate which may be infiltrated with one or more of an antibiotic, a growth factor, a differentiation factors, a cytokine, a drug, or a combination of these agents.