3D Printed Gyroid Lattice Bone Scaffold

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Solution Overview

Problem

Current bone grafts face challenges such as brittleness, lack of regenerative capabilities, cytotoxicity, and complications like pain, infection, and nerve damage during harvesting, along with limited supply and poor integration with surrounding tissue.

Innovation Solution

A composite bone graft scaffold is developed by integrating 3D printed gyroid lattice structures with chitosan-gelatin cryogels, providing a mechanically stable, macroporous framework that supports cellular adhesion and proliferation while promoting bone regeneration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If cryogels are used as bone graft scaffolds, then biocompatibility and porosity are improved, but mechanical strength is insufficient

Engineering Contradiction:

Improvemechanical strengthVSAvoidstructural stability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent combines 3D printed lattice structures with cryogel materials to create a composite scaffold system. The lattice structure provides the mechanical framework while the cryogel fills the spaces to provide biocompatibility and porosity, thus merging the advantages of both components to resolve the contradiction between mechanical strength and structural stability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses composite materials by integrating the rigid lattice structure with the soft cryogel material. This composite approach allows the scaffold to simultaneously achieve the mechanical properties needed for structural stability and the biological properties needed for bone regeneration, resolving the contradiction between strength and reliability.

Inventive Principle:

Principle #40Composite materials

2Strength

If 3D printing is used to create lattice structures, then mechanical strength is improved, but porosity and resolution are insufficient

Engineering Contradiction:

Improvemechanical strengthVSAvoidpore resolution

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent merges 3D printed lattice structures with cryogel-filled spaces to create a hybrid scaffold. The 3D printing provides the macro-scale mechanical framework with adequate strength, while the cryogel infiltration provides the micro-scale porosity and surface complexity needed for cell attachment, thus resolving the contradiction between mechanical strength and manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If bone cements are used to fill bone defects, then mechanical support is provided, but regenerative capabilities and biocompatibility are poor

Engineering Contradiction:

Improvemechanical supportVSAvoidcytotoxicity

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent uses porous cryogel materials instead of dense bone cements. The porous structure allows for cell infiltration, nutrient transport, and waste removal, providing regenerative capabilities while maintaining mechanical support through the lattice framework, thus resolving the contradiction between mechanical support and biocompatibility.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention creates a composite system where the lattice structure provides mechanical support similar to bone cements, but the cryogel material replaces the cytotoxic components with biocompatible, regenerative materials, thus achieving both mechanical support and improved biocompatibility.

Inventive Principle:

Principle #40Composite materials

4Reliability

If traditional bone grafting is performed, then bone regeneration is promoted, but donor site complications and limited supply occur

Engineering Contradiction:

Improvebone regenerationVSAvoiddonor site complications

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates synthetic scaffolds that eliminate the need for donor bone harvesting. The scaffolds are designed to self-support bone regeneration through their porous structure and biocompatible materials, providing the regenerative function without the harmful effects of donor site complications, thus resolving the contradiction between reliability and harmful factors.

Inventive Principle:

Principle #25Self-service

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 composite scaffold achieves improved mechanical strength, porosity, and swelling capacity compared to traditional cryogels, facilitating effective bone tissue regeneration and integration with minimal immunogenic response.

Implementation Method 1

freezing a cryogel solution, pouring the cryogel solution onto a lattice structure having a triply periodic minimal surface (TPMS) shape, and freezing the cryogel solution poured onto the lattice structure to form an integrated bone graft scaffold

Methodology Applied

Scientific EffectFreezing: Freezing

Data Source

PatentUS20250090727A1Integrated biomaterial scaffold with 3D printed lattice backbone

Publication Date: 2025.03.20 TRUSTEES OF DARTMOUTH COLLEGE THE

AI summary

A bone graft scaffold including the combination of a lattice structure having a triply periodic minimal surface (TPMS) shape and a cryogel solution disposed within the lattice structure. Also described is a method of making an integrated bone graft scaffold by freezing a cryogel solution, pouring the cryogel solution onto a scaffold, and freezing the cryogel solution poured onto the lattice structure to form an integrated bone graft scaffold. The cryogel solution may be a chitosan-gelatin cryogel and the lattice structure may be a 3D printed gyroid lattice structure.