Box-Behnken Design of Experiments Investigation of Hydroxyapatite Synthesis for Orthopedic Applications

Abstract

Physicochemical properties of hydroxyapatite (HAp) synthesized by the chemical precipitation method are heavily dependent on the chosen process parameters. A Box-Behnken three-level experimental design was therefore, chosen to determine the optimum set of process parameters and their effect on various HAp characteristics. These effects were quantified using design of experiments (DoE) to develop mathematical models using the Box-Behnken design, in terms of the chemical precipitation process parameters. Findings from this research show that the HAp possessing optimum powder characteristics for orthopedic application via a thermal spray technique can therefore be prepared using the following chemical precipitation process parameters: reaction temperature 60 °C, ripening time 48 h, and stirring speed 1500 rpm using high reagent concentrations. Ripening time and stirring speed significantly affected the final phase purity for the experimental conditions of the Box-Behnken design. An increase in both the ripening time (36-48 h) and stirring speed (1200-1500 rpm) was found to result in an increase of phase purity from 47(±2)% to 85(±2)%. Crystallinity, crystallite size, lattice parameters, and mean particle size were also optimized within the research to find desired settings to achieve results suitable for FDA regulations.