Abstract
This study proposes a new type of calcium phosphate (CaP) scaffolds with a continuously gradient macro/microporous structure using the ceramic/camphene-based 3D extrusion process. Green filaments with a continuously gradient core/shell structure were successfully produced by extruding a bilayered feedrod comprised of a CaP/camphene mixture lower part and a pure camphene upper part. The extruded filaments were then deposited in a controlled manner to construct triangular prisms, followed by the assembly process for the production of CaP scaffolds with a gradient core/shell structure. In addition, a gradient microporous structure was created by heat-treating the green body at 43 °C to induce the overgrowth of camphene dendrites in the CaP/camphene walls. The produced CaP scaffold showed a highly macroporous structure within its inner core, where the size of macrochannels increased gradually with an increase in the distance from the outer shell, while relatively larger micropores were created in the outer shell.
Highlights
Biocompatible, biodegradable ceramics with an open porous structure have been used widely as bone scaffolds for the repair of diseased and damaged bone tissues [1]
The bottom made of a calcium phosphate (CaP)/camphene mixture was formed at the early stage of extrusion
To induce the overgrowth of camphene dendrites formed in the CaP/camphene walls, the green body was heat-treated at 43 ◦ C close to the solidification point of a CaP/camphene slurry [12]
Summary
Biocompatible, biodegradable ceramics with an open porous structure have been used widely as bone scaffolds for the repair of diseased and damaged bone tissues [1]. When formulated into porous structures, these materials have relatively low mechanical strengths compared to those of natural bones and would not effectively withstand loads applied to bone defects [4,5]. Their mechanical properties severely decrease with increasing porosity, which has been one of the biggest obstacles for the production of porous ceramic scaffolds with biomimetic mechanical and biological functions. Such aligned porous structures can be created using unidirectional freeze-casting
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