DLP Bone Graft Manufacturing Precision
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Solution Overview
Problem
Existing methods for manufacturing bone graft materials using 3D printing face limitations in precision and design due to the use of FDM systems, which result in inadequate bone volume and the need for shielding membranes, especially in patients lacking bone tissue.
Innovation Solution
A method involving the dispersion of calcium phosphate-based ceramics in a solvent, followed by the production of a photocurable resin composition with a crosslinking agent and photoinitiator, and subsequent 3D printing using a DLP system to create a bone graft material with improved precision and compressive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If FDM-type 3D printing is used to manufacture bone graft material, then the manufacturing process is simple and continuous output is achieved, but manufacturing precision deteriorates and design is restricted
Solution Approach 1:
The patent replaces the mechanical extrusion-based FDM printing system with a photopolymerization-based DLP printing system. The DLP system uses light (optical field) to cure liquid resin layer by layer, eliminating the mechanical nozzle movement and extrusion processes of FDM. This substitution enables higher precision (50-100 micrometer resolution) while maintaining ease of manufacture through automated digital light processing, directly resolving the contradiction between manufacturing simplicity and precision.
2Adaptability or versatility
If particle-type bone graft material is used, then the material can be applied to patients with bone tissue deficiency, but sufficient bone volume cannot be obtained and shielding membrane is required
Solution Approach 1:
The patent changes the physical state and structural parameters of the bone graft material from discrete particles to a continuous 3D printed structure with controlled porosity (40-60% pore space). This parameter change allows the material to maintain its adaptability for bone regeneration while achieving sufficient volume retention and structural integrity to eliminate the need for shielding membranes. The controlled porous structure enables bone ingrowth while maintaining form stability.
3Volume of stationary object
If excessive amount of bone graft material is introduced to protect surgical site, then bone volume is maintained, but surgical process becomes difficult and starting material consumption increases
Solution Approach 1:
The patent segments the bone graft material into a precisely fitted 3D printed structure that matches the patient's specific anatomical defect. Rather than using excessive bulk material, the segmented and customized structure provides exact coverage and support where needed. This segmentation approach maintains sufficient bone volume for protection while simplifying the surgical insertion process and reducing material consumption to only what is necessary for the specific defect.
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 method enables the production of bone graft materials with enhanced precision and compressive strength, eliminating the need for shielding membranes and ensuring sufficient bone volume, particularly beneficial for patients with bone tissue deficiencies.
Implementation Method 1
producing a photocurable resin composition by adding a binder resin including a crosslinking agent and a photoinitiator
Implementation Method 2
dispersing a powder material including calcium phosphate-based ceramics in a solvent
Implementation Method 3
debinding and sintering organic materials remaining in the bone graft material molded body
Implementation Method 4
debinding and sintering organic materials remaining in the bone graft material molded body
Data Source
AI summary
The present invention relates to a method for manufacturing a bone graft material using 3D printing of a DLP system. The method includes (1) dispersing a powder material including calcium phosphate-based ceramics in a solvent; (2) recovering the calcium phosphate-based ceramics by removing the solvent from a solution in which the calcium phosphate-based ceramic material is dispersed in Step 1; (3) producing a photocurable resin composition by adding a binder resin including a crosslinking agent and a photoinitiator to the calcium phosphate-based ceramics obtained in Step 2; (4) performing 3D rapid prototyping on a bone graft material molded body from the composition for a bone graft material produced in Step 3 by 3D printing of a DLP system; and (5) debinding and sintering organic materials remaining in the bone graft material molded body subjected to prototyping in Step 4.