“Mg” Bone

“Mg” Bone: Ink extrusion-based additive manufacturing of Mg implants

Dong, J. (TU Delft Biomaterials & Tissue Biomechanics)

Zadpoor, A.A. (promotor)
Zhou, J. (promotor)

Delft University of Technology

2023-03-22

The treatment of largy bone defect remains challenging in clinics. All the clinically available bone grafts have their own limitations and are not ideal for the treatment. Therefore, developing a new generation of suitable bone substitutes is urgently needed. In the recent years, porous magnesium (Mg) has been extensively studied for orthopedic applications owing to its biodegradability, favorable mechanical properties, and osteopromotive ability. The recent advances in additive manufacturing (AM) provide unprecedented opportunities to design and fabricate porous Mg scaffolds with interconnected porous structures that are favorable for the adhesion and proliferation of bone cells. However, powder bed fusion AM, which is the most commonly used AM technique for fabricating metal structures, has encountered many difficulties in manufacturing Mg due to safety concerns, excessive oxidation, and undesirable compositional variation due to the low boiling temperature of Mg. To alleviate these difficulties, alternative AM techniques that can create highly porous structures at room temperature are highly sought after. The aim of this research was to develop a room-temperature AM technique for manufacturing porous Mg and to characterize the fabricated Mg-based scaffolds in different aspects relevant to their potential applications as bone implants.
In this thesis work, we, for the first time, successfully employed extrusion-based 3D printing techniques to fabricate biodegradable porous Mg and Mg-based scaffolds for application in orthopedics. We started with the optimization of the formulated binder system, the printing process, and the subsequent liquid-phase sintering process for the AM of Mg and Mg-based scaffolds. On this basis, a series of Mg and Mg-based porous scaffolds, including Mg alloy and Mg matrix composite scaffolds were successfully fabricated. Then, we conducted comprehensive studies on the microstructure, geometrical characteristics, in vitro biodegradation behavior, mechanical properties, and the in vitro biodegradation and the responses of preosteoblast MC3T3-E1 cells to the fabricated scaffolds to evaluate the ability of the fabricated scaffolds to satisfy the requirements of ideal bone-substituting biomaterials. By modifying the alloy composition and adding bioceramic components, the properties of the Mg scaffolds required were significantly improved as compared to those of the pure Mg specimens. The fabricated Mg-matrix composite scaffolds were shown to be the most promising materials to be further developed for bone substitution. Surface modification could also contribute to bringing the fabricated Mg scaffolds closer to meeting the requirements. Therefore, with proper material design and surface modification, the Mg-based scaffolds fabricated using extrusion-based 3D printing technique constitute a new category of porous Mg-based biomaterials that hold great promise for application as bone substitutes.

additive manufacturing
scaffold
biodegradation
mechanical property
biocompatibility
magnesium

https://doi.org/10.4233/uuid:800cbeba-7ad9-440f-acf2-68cdd5bbbb4b

978-94-6384-426-0

Institutional Repository

doctoral thesis

© 2023 J. Dong