Calcium-based triphasic powder synthesis for strengthening 3D printed bone scaffolds

This study aims to improve the mechanical properties of biocompatible ceramic materials, which are known for their superior potential to integrate with bone compared to metallic implants. However, achieving sufficient mechanical strength, particularly for weight-bearing areas, poses a challenge. Hydroxyapatite (HA) powder is synthesized, taking into consideration the mechanical mixing and aging effects to achieve the desired composition and properties. The synthesized HA powder undergoes calcination under various atmospheres to assess its impact on the crystal structure. The study also explores the coating of HA particles with silicon dioxide (SiO2) using tetraethyl orthosilicate (TEOS) to enhance surface modification and wettability. This process results in a triphasic powder consisting of HA, tricalcium phosphate (TCP), and calcium phosphate silicate (CPS). The morphology of the powder is analyzed using techniques such as energy-dispersive X-ray spectroscopy (EDX), scanning electron microscopy (SEM), and X-ray diffraction (XRD). Moreover, a refined sintering procedure is developed to minimize cracking volume, leading to a significant 117 % increase in compressive strength compared to commercial materials. Finally, the powder is optimized for 3D printing by adding water, simplifying its use in biomedical applications.