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Li M, Huang S, Willems E, Soete J, Inokoshi M, Van Meerbeek B, Vleugels J, Zhang F. UV-Curing Assisted Direct Ink Writing of Dense, Crack-Free, and High-Performance Zirconia-Based Composites With Aligned Alumina Platelets. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2024; 36:e2306764. [PMID: 37986661 DOI: 10.1002/adma.202306764] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/10/2023] [Revised: 11/02/2023] [Indexed: 11/22/2023]
Abstract
Additive manufacturing (AM) of high-performance structural ceramic components with comparative strength and toughness as conventionally manufactured ceramics remains challenging. Here, a UV-curing approach is integrated in direct ink writing (DIW), taking advantage from DIW to enable an easy use of high solid-loading pastes and multi-layered materials with compositional changes; while, avoiding drying problems. UV-curable opaque zirconia-based slurries with a solid loading of 51 vol% are developed to fabricate dense and crack-free alumina-toughened zirconia (ATZ) containing 3 wt% alumina platelets. Importantly, a non-reactive diluent is added to relieve polymerization-induced internal stresses, avoid subsequent warping and cracking, and facilitate the de-binding. For the first time, UV-curing assisted DIW-printed ceramic after sintering reveals even better mechanical properties than that processed by a conventional pressing. This is attributed to the aligned alumina platelets, enhancing crack deflection and improving the fracture toughness from 6.8 ± 0.3 MPa m0.5 (compacted) to 7.4 ± 0.3 MPa m0.5 (DIW). The four-point bending strength of the DIW ATZ (1009 ± 93 MPa) is also higher than that of the conventionally manufactured equivalent (861 ± 68 MPa). Besides homogeneous ceramic, laminate structures are demonstrated. This work provides a valuable hybrid approach to additively manufacture tough and strong ceramic components.
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Affiliation(s)
- Maoyin Li
- Department of Materials Engineering, KU Leuven, Kasteelpark Arenberg 44, Leuven, B-3001, Belgium
- Department of Oral Health Sciences, KU Leuven, BIOMAT - Biomaterials Research group and UZ Leuven (University Hospitals Leuven), Dentistry, Kapucijnenvoer 7 block a, Leuven, B-3000, Belgium
| | - Shuigen Huang
- Department of Materials Engineering, KU Leuven, Kasteelpark Arenberg 44, Leuven, B-3001, Belgium
| | - Evita Willems
- Department of Materials Engineering, KU Leuven, Kasteelpark Arenberg 44, Leuven, B-3001, Belgium
| | - Jeroen Soete
- Department of Materials Engineering, KU Leuven, Kasteelpark Arenberg 44, Leuven, B-3001, Belgium
| | - Masanao Inokoshi
- Department of Gerodontology and Oral Rehabilitation, Graduate School of Medical and Dental Sciences, Tokyo Medical and Dental University, 1-5-45 Yushima, Bunkyo, Tokyo, 113-8549, Japan
| | - Bart Van Meerbeek
- Department of Oral Health Sciences, KU Leuven, BIOMAT - Biomaterials Research group and UZ Leuven (University Hospitals Leuven), Dentistry, Kapucijnenvoer 7 block a, Leuven, B-3000, Belgium
| | - Jef Vleugels
- Department of Materials Engineering, KU Leuven, Kasteelpark Arenberg 44, Leuven, B-3001, Belgium
| | - Fei Zhang
- Department of Materials Engineering, KU Leuven, Kasteelpark Arenberg 44, Leuven, B-3001, Belgium
- Department of Oral Health Sciences, KU Leuven, BIOMAT - Biomaterials Research group and UZ Leuven (University Hospitals Leuven), Dentistry, Kapucijnenvoer 7 block a, Leuven, B-3000, Belgium
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Wang C, Zhou Y. Sacrificial biomaterials in 3D fabrication of scaffolds for tissue engineering applications. J Biomed Mater Res B Appl Biomater 2024; 112:e35312. [PMID: 37572033 DOI: 10.1002/jbm.b.35312] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/23/2023] [Revised: 07/05/2023] [Accepted: 07/31/2023] [Indexed: 08/14/2023]
Abstract
Three-dimensional (3D) printing technology has progressed exceedingly in the area of tissue engineering. Despite the tremendous potential of 3D printing, building scaffolds with complex 3D structure, especially with soft materials, still exist as a challenge due to the low mechanical strength of the materials. Recently, sacrificial materials have emerged as a possible solution to address this issue, as they could serve as temporary support or templates to fabricate scaffolds with intricate geometries, porous structures, and interconnected channels without deformation or collapse. Here, we outline the various types of scaffold biomaterials with sacrificial materials, their pros and cons, and mechanisms behind the sacrificial material removal, compare the manufacturing methods such as salt leaching, electrospinning, injection-molding, bioprinting with advantages and disadvantages, and discuss how sacrificial materials could be applied in tissue-specific applications to achieve desired structures. We finally conclude with future challenges and potential research directions.
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Affiliation(s)
- Chi Wang
- Systems Science and Industrial Engineering, Binghamton University, Binghamton, New York, USA
| | - Yingge Zhou
- Systems Science and Industrial Engineering, Binghamton University, Binghamton, New York, USA
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Llorens JS, Barbera L, Demirörs AF, Studart AR. Light-Based 3D Printing of Complex-Shaped Photonic Colloidal Glasses. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2023; 35:e2302868. [PMID: 37470316 DOI: 10.1002/adma.202302868] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/28/2023] [Revised: 06/25/2023] [Accepted: 07/14/2023] [Indexed: 07/21/2023]
Abstract
Colloidal glasses display angle-independent structural color that is tunable by the size and local arrangement of sub-micrometer particles. While films, droplets, and microcapsules with isotropic structural color have been demonstrated, the shaping of colloidal glasses in three dimensions remains an open manufacturing challenge. Here, a light-based printing platform for the shaping of colloidal glasses into 3D objects featuring complex geometries and vivid structural color after thermal treatment is reported. Rheology, photopolymerization, and calcination experiments are performed to design the photoreactive resins leading to printable colloidal glasses. With the help of microscopy, scattering, and optical characterization, it is shown that the photonic properties of the printed objects reflect the locally ordered microstructure of the glass. The capability of the platform in creating 3D objects with isotropic structural color is illustrated by printing lattices and miniaturized sculpture replicas with unique shapes and multimaterial designs.
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Affiliation(s)
| | - Lorenzo Barbera
- Complex Materials, Department of Materials, ETH Zurich, 8093, Zurich, Switzerland
| | - Ahmet F Demirörs
- Complex Materials, Department of Materials, ETH Zurich, 8093, Zurich, Switzerland
- Soft Matter and Photonics, Department of Physics, University of Fribourg, 1700, Fribourg, Switzerland
| | - Andre R Studart
- Complex Materials, Department of Materials, ETH Zurich, 8093, Zurich, Switzerland
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Lee SS, Kleger N, Kuhn GA, Greutert H, Du X, Smit T, Studart AR, Ferguson SJ. A 3D-Printed Assemblable Bespoke Scaffold as a Versatile Microcryogel Carrier for Site-Specific Regenerative Medicine. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2023; 35:e2302008. [PMID: 37632210 DOI: 10.1002/adma.202302008] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/02/2023] [Revised: 07/22/2023] [Indexed: 08/27/2023]
Abstract
Advances in additive manufacturing have led to diverse patient-specific implant designs utilizing computed tomography, but this requires intensive work and financial implications. Here, Digital Light Processing is used to fabricate a hive-structured assemblable bespoke scaffold (HIVE). HIVE can be manually assembled in any shape/size with ease, so a surgeon can create a scaffold that will best fit a defect before implantation. Simultaneously, it can have site-specific treatments by working as a carrier filled with microcryogels (MC) incorporating different biological factors in different pockets of HIVE. After characterization, possible site-specific applications are investigated by utilizing HIVE as a versatile carrier with incorporated treatments such as growth factors (GF), bioceramic, or cells. HIVE as a GF-carrier shows a controlled release of bone morphogenetic protein/vascular endothelial growth factor (BMP/VEGF) and induced osteogenesis/angiogenesis from human mesenchymal stem cells (hMSC)/human umbilical vein endothelial cells (HUVECs). Furthermore, as a bioceramic-carrier, HIVE demonstrates enhanced mineralization and osteogenesis, and as a HUVEC carrier, it upregulates both osteogenic and angiogenic gene expression of hMSCs. HIVE with different combinations of MCs yields a distinct local effect and successful cell migration is confirmed within assembled HIVEs. Finally, an in vivo rat subcutaneous implantation demonstrates site-specific osteogenesis and angiogenesis.
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Affiliation(s)
- Seunghun S Lee
- Institute for Biomechanics, Department of Health Sciences and Technology, ETH Zurich, Zurich, 8092, Switzerland
| | - Nicole Kleger
- Complex Materials, Department of Materials, ETH Zurich, Zurich, 8093, Switzerland
| | - Gisela A Kuhn
- Institute for Biomechanics, Department of Health Sciences and Technology, ETH Zurich, Zurich, 8092, Switzerland
| | - Helen Greutert
- Institute for Biomechanics, Department of Health Sciences and Technology, ETH Zurich, Zurich, 8092, Switzerland
| | - Xiaoyu Du
- Institute for Biomechanics, Department of Health Sciences and Technology, ETH Zurich, Zurich, 8092, Switzerland
| | - Thijs Smit
- Institute for Biomechanics, Department of Health Sciences and Technology, ETH Zurich, Zurich, 8092, Switzerland
| | - André R Studart
- Complex Materials, Department of Materials, ETH Zurich, Zurich, 8093, Switzerland
| | - Stephen J Ferguson
- Institute for Biomechanics, Department of Health Sciences and Technology, ETH Zurich, Zurich, 8092, Switzerland
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