Rapid manufacturing of bioceramic implants by direct writing.

Abstract: A new process for the manufacture of customised implants for replacing damaged or diseased bone is being developed at DMU under a UK Government funded project – TSB Direct Writing of Bioceramic Implants. The new process is based on the extrusion of a fine bead of colloidal slurry which is then rapidly cooled to below -40oC to initiate an irreversible freeze casting reaction. When the slurry is returned to room temperature it remains a brittle solid which can be fired at elevated temperatures to generate the required mechanical properties. By sequentially depositing layers of material it is possible to generate a complex 3D object which has an internal lattice structure which enables rapid integration of the implant with the surrounding natural bone to produce a secure, long lasting repair. In this paper the results extrusion and freeze casting trials will be presented and discussed.