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JOURNAL OF MATERIALS SCIENCE: MATERIALS IN MEDICINE 12 (2001) 471±478 Hydroxyapatite implants with designed internal architecture T.-M. G. CHU 1 , J. W. HALLORAN 2 , S. J. HOLLISTER 1 , S. E. FEINBERG 3 1 Department of Biomedical Engineering, University of Michigan, Ann Arbor, MI 48109, USA 2 Department of Materials Science and Engineering, University of Michigan, Ann Arbor, MI 48109, USA 3 Department of Surgery, University of Michigan, Ann Arbor, MI 48109, USA E-mail: [email protected] Porous hydroxyapatite (HA) has been used as a bone graft material in the clinics for decades. Traditionally, the pores in these HAs are either obtained from the coralline exoskeletal patterns or from the embedded organic particles in the starting HA powder. Both processes offer very limited control on the pore structure. A new method for manufacturing porous HA with designed pore channels has been developed. This method is essentially a lost-mold technique with negative molds made with Stereolithography and a highly loaded curable HA suspension as the ceramic carrier. Implants with designed channels and connection patterns were ®rst generated from a Computer-Aided-Design (CAD) software and Computer Tomography (CT) data. The negative images of the designs were used to build the molds on a stereolithography apparatus with epoxy resins. A 40 vol% HA suspension in propoxylated neopentyl glycol diacrylate (PNPGDA) and iso-bornyl acrylate (IBA) was formulated. HA suspension was cast into the epoxy molds and cured into solid at 85 C. The molds and acrylate binders were removed by pyrolysis, followed by HA green body sintering. With this method, implants with six different channel designs were built successfully and the designed channels were reproduced in the sintered HA implants. The channels created in the sintered HA implants were between 366 mm and 968 mm in diameter with standard deviations of 50 mm or less. The porosity created by the channels were between 26% and 52%. The results show that HA implants with designed connection pattern and well controled channel size can be built with the technique developed in this study. # 2001 Kluwer Academic Publishers 1. Introduction Hydroxyapatite (HA) is a calcium phosphate that makes up the majority of the inorganic component of human bones and teeth. HA prepared in porous blocks or granules has been studied extensively as a bone graft material [1, 2]. The compatibility of these porous HA implants with bone tissues has been demonstrated in several researches [3±7]. Several manufacturing tech- niques have been developed for making these porous HAs. Two methods are most widely used. The ®rst method was developed by Roy and Linnehan by using a hydrothermal exchange process to derive porous HA from reef building corals [8]. The calcium carbonate in the coral exoskeleton is converted into HA with the structural pattern of the coral exoskeleton preserved. The connecting channels in the ®nal HA implants are provided by the natural coral exoskeleton architecture. Implants of this type have been studied extensively [3± 5, 7, 9, 10]. A second method of making porous HA involves embedding organic particles, such as polyvinyl butyral [11, 12], naphthalene [13], and acrylic beads [14] in HA powder. HA powder is dry-pressed along with the organic particles. At high temperature, the organic particles are pyrolyzed, leaving pores in the size range of the original particle. The green body is then sintered into ceramics. In both processes, the control over the internal porous structure of the implants is very minimal. Undesirable isolated pores and blind ends are common in implants manufactured with the organic particle tech- nique [2]. The coralline HA only contains the porous structure provided by the exoskeleton pattern of the harvested coral. The hydrothermal exchange process does not offer any control over the porous structure. In this research, we have explored a new technique of manufacturing porous HA implants with designed channel pattern. This process is essentially a lost-mold shape forming process involving the use of StereoLithography (SL) and a highly loaded ``reactive ceramic suspension''. SL is a technique capable of taking the 3D computer scanning image or the computer design of an object and constructs a three-dimensional repre- sentation of the object from epoxy resin [15]. Several 0957±4530 # 2001 Kluwer Academic Publishers 471

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