Feedstock quality control for additive manufacturing of bioceramics

Hydroxyapatite is a biocompatible ceramic material used in implants and scaffolds due to its similarity to bone tissue promoting osteoblast proliferation and bone tissue formation. However, commercially available powders can vary dramatically in particle size and morphology, influencing the characteristics of produced components and causing issues such as high shrinkage and poor mechanical properties.

There is a critical need for businesses to control the quality of the raw materials used in hydroxyapatite research and manufacturing to obtain reliable and consistent products. This case study compares the performance of hydroxyapatite from two separate suppliers and investigates the influence of powder size and morphology on the performance of a 3D-printed part.

By comparing powders from two suppliers and linking particle morphology and size distribution to paste rheology, print quality, shrinkage and final density, the work highlights why robust feedstock characterisation is essential for reliable, repeatable additive manufacturing of patient-specific implants and scaffolds.

The work was undertaken at The AMRICC Centre on behalf of MICG partner Lucideon, and was supported and partly funded by UK Research and Innovation through the Strength in Places Fund Programme.

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