Synthesis of Calcium Phosphate Powders in Nonaqueous Media for Stereolithography 3D Printing

Abstract

Methods were presented to synthesize tricalcium phosphate Ca3(PO4)2 (TCP), calcium pyrophosphate Ca2P2O7 (CPP), and TCP/CPP composites in nonaqueous media in the temperature range 25–300°C. It was shown that solvo- and ionothermal synthesis methods can give phosphates of complex composition. The phase composition, micromorphology, and particle size distribution of the obtained powders and their evolution during synthesis were described. The synthesis at 110°C while slowly adding ammonium hydrophosphate to a solution of calcium ethylene glycolate in ethylene glycol gives a nanocrystalline β-TCP powder with an average size of aggregates of platy crystals of 150 nm and a distribution width of 50 nm. The morphological characteristics and sinterability of the powders synthesized in solutions in ethylene glycol make them suitable for producing macroporous ceramics by stereolithography 3D printing methods.