Novel technology for implants manufacturing from 3D printable reinforced composite filaments for guided bone regeneration
PN-III-P2-2.1-PED-2021-1650
contract number 583PED/2022

Compared to the limited market of products destined for bone reconstructive surgery and the high-patient-risks of current approaches, this project is a necessity to solve the absence of 3D products with optimal geometry, internal architecture and mechanical properties for customized compatibility with natural bone and a rapid repair of defects with variable dimensions. The overall goal of the project is to develop and promote a new reproducible and sustainable manufacturing technology for the products fabrication by 3D printing, using as platform the previously implemented technology for the synthesis of hydroxyapatite derived from bovine bone biogenic resources and the project team`s experience in the field. Composite filaments with printable features will be obtained based on natural hydroxyapatite and two polymers, one of which will be of natural origin. Also, superior and adaptable mechanical characteristics will be ensured by reinforcing the ceramic matrix with multi-layer graphene-based materials. Further, the filaments will be used for 3D printing of products with regular and random internal architecture (based on a new STL file developed within the project). Afterwards, the products will be tested as to evaluate their performance as potential bone replacements. In this regard, a patent application will be filed. The proposed topic is new and challenging for the project team, but all the premises are fulfilled through the team`s synergy and previous research experience. The concept and experimental testing of the possibility of embedding naturally derived ceramic particles into a polymer matrix of natural origin were also demonstrated and reported by the team members as viable for achieving the project objectives.

GENERAL OBJECTIVE

Development and implementation of a new, sustainable and reproducible technology for manufacturing biocompatible 3D printed composite products with modelled architectural and mechanical characteristics.

RESULTS SUMARY

The innovative technology developed in this project focused on the fabrication of customized bone implants using composite materials based on polylactic acid (PLA), biogenic hydroxyapatite (HA) and graphene nanoplatelets (GNPs) that can be used for 3D printing of type scaffold through the Fused Deposition Modeling (FDM) technique. These implants are designed to be biocompatible, biodegradable and promote guided bone regeneration. The long-term biocompatibility of a material used in tissue engineering is its ability to successfully integrate into the host tissue without inducing an adverse immune reaction in the human body. For this to be possible, the composition of biomaterials must not contain toxic elements, and their surface must present characteristics capable of inducing cellular responses beneficial to the osseointegration process. After the optimal controlled modulation of the composition of the precursor materials mentioned above for the development of composite materials, ensuring an appropriate internal geometry and degree of porosity at the level of the scaffold structure, according to the personalized medical requirements at the level of the patient, is a key factor for a bone regeneration fast and efficient.

OBJECTIVE 2022

The development of studies and analyzes on bone augmentation materials used in reconstructive surgery, on biomaterials from natural origin and on technologies used for processing of custom biomimetic implants.

OBJECTIVE 2023

Complex characterization of the obtained composite materials.

OBJECTIVE 2024

Selection of the optimal manufacturing technology for 3D printed biomimetic products and comprehensive in vitro evaluation of composite materials.