Abstract
A novel process, namely replication combined with electrospraying, was used to fabricate bioceramic (zirconia) scaffolds with the intention of improving the mechanical function of hard tissue engineering scaffolds. A comparative study was carried out on the microstructure and mechanical properties of zirconia foams prepared by this new process or by the conventional slurry‐dip coating method. After forming the green bodies, they were subjected to a sintering heat treatment at 1450°C for 5 h. It was found that the number and size of microcracks and micropores can be reduced in foams prepared by electrospraying in comparison with those prepared by slurry‐dip coating. The values of compressive mechanical strength and Young's modulus were found to be collectively higher for scaffolds prepared by electrospraying than for those prepared by slurry‐dip coating. Moreover, the mechanical reliability was improved in foams produced by the electrospraying technique. The improvement is attributable to the reduction in the population and size of microcracks and micropores.
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