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Novel Ceramic Composites for Personalized 3D Structures

M. Ahlhelm, E. Schwarzer, U. Scheithauer, T. Moritz, A. Michaelis

Fraunhofer Institut für Keramische Technologien und Systeme (IKTS), Winterbergstraße 28, D-01277 Dresden, Germany

received November 2, 2016, received in revised form December 21, 2016, accepted January 25, 2017

Vol. 8, No. 1, Pages 91-100   DOI: 10.4416/JCST2016-00093

Abstract

The objective of the presented work is to further introduce a new hybrid shaping technique and develop novel porous, near-net shaped composite structures e.g. for personalized bone replacement materials.

The suspension-based additive manufacturing technique lithography-based ceramic manufacturing enables high structural resolution and the manufacturing of dense (> 99 %) ceramic components with high performance compared to other available AM techniques. On the other hand, freeze foaming offers the possibility to achieve mainly open porous and interconnected sponge-like structures that provably allow the ingrowth and differentiation of human mesenchymal stem cells (hMSCs). The near-net shaping feasibility of this foaming technique was used to foam the inner contours of complex LCM-manufactured ceramic shell structures in the shape of a femoral bone model. After a co-sintering step, they combine to structural composites with dense and porous features in one single 3D structure. This contribution therefore provides insides into a new line of technology comprising a new degree of freedom in personalization and application such as bone replacement materials.

Keywords

Bioceramics, bone replacement materials, freeze foaming, LCM, hybrid shaping

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