Ceramic Implant With Dense Shell And Pore Channels
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Solution Overview
Problem
Current methods for producing large numbers of porous ceramic implants with defined porosity are inefficient, costly, and lack the necessary strength and biocompatibility for effective cell ingrowth and nutrient supply.
Innovation Solution
A ceramic implant with a load-bearing, dense shell and a porous filling featuring a percolating pore network and aligned pore channels, manufactured using ceramic two-component injection molding, ensuring high primary and secondary strength, optimal pore size for cell growth, and hydraulic connectivity for nutrient supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If porous materials are used to promote cell adhesion and growth, then biological compatibility and cell proliferation are improved, but mechanical strength and structural stability deteriorate
Solution Approach 1:
The implant features a dual-structure design where the outer shell maintains high density (porosity <3 vol%) for mechanical strength, while the inner filling has high porosity (15-90 vol%) for biological compatibility. This spatial differentiation of material properties resolves the contradiction between strength and biocompatibility.
Solution Approach 2:
The implant combines two ceramic materials with different properties: a dense load-bearing shell and a porous bioactive filling. This composite structure allows each material to perform its optimal function - the dense shell provides structural integrity while the porous filling promotes cell growth.
2Reliability
If high porosity is used to enable nutrient supply and cell growth, then biological function is improved, but structural stability and fracture resistance deteriorate
Solution Approach 1:
The porous filling is confined to the inner region where biological function is needed, while the outer shell maintains high density for structural stability. The defined pore channels (0.1-2 mm diameter) provide controlled pathways for nutrient transport without compromising overall structure.
Solution Approach 2:
The implant is segmented into functional zones: the outer shell handles mechanical loading, the pore channels provide fluid transport pathways, and the porous filling supports cell growth. This segmentation allows each zone to optimize its specific function without compromising others.
3Ease of manufacture
If conventional production methods are used for porous ceramic implants, then manufacturing simplicity is maintained, but production efficiency and cost-effectiveness deteriorate
Solution Approach 1:
The patent combines the shell and filling into a single monolithic ceramic component manufactured in one injection molding cycle. The two-component feedstock system (metallic for shell, ceramic for filling) is processed simultaneously, eliminating separate manufacturing and assembly steps while maintaining production efficiency.
Solution Approach 2:
The invention uses ceramic injection molding with specific parameter optimizations: feedstock composition ( ceramic powder + binder + pore-forming agents), processing temperature ranges, and sintering parameters. These controlled parameter changes enable high-volume production with consistent quality and reduced costs.
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 implant provides a strong, biocompatible substrate for bone ingrowth with enhanced nutrient supply, achieving improved anchoring and growth conditions through its design and manufacturing process.
Implementation Method 1
The pore size in the porous material of the filling is in the range of 2 to 400 μm, preferably in the range of 5 to 200 μm. The porous filling should exhibit a permeable, percolating pore network.
Implementation Method 2
The wall of the pore channels is designed to allow fluid ingress through the porous ceramic filling and to have a pronounced surface roughness with a mean roughness depth of Rz 10–250 μm, preferably Rz 20–200 μm. This enables intensive interlocking of the ingrowing bone with the structure of the pore channel walls.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
The invention relates to a ceramic component that consists of a shell, a porous filler material, and pore channels which pass through said filler material.