Lithoz GmbH
Bioceramics can be used as materials for implants, whether permanent ones for load-bearing devices or bioresorbable and bioactive ones for bone regeneration. Due to the unique design freedom of additive manufacturing it is possible to produce implants and medical devices tailored to patients needs. The process of lithography-based ceramic manufacturing (LCM) paves the way for modern medical applications and the production of complex designs, as well as designed porosity of bioceramics. The LCM process represents a vat polymerization technique, manufacturing greenparts through layerwise curing of a photosensitive ceramic-filled suspension. After a thermal treatment - debinding and sintering - the final properties of the bioceramics are achieved. This work focuses on materials for LCM and their applications in the field of medical technologies. Complex geometries using bioabsorbable and bioactive materials such as tricalcium phosphate (TCP) and hydroxyapatite (HA) can be created with a wall tickness up to 8 mm and adjustable densities of 92 - 99 % in bulk. These LCM implants can serve as scaffold structures for bone reconstruction after bone injuries of critical defect size, avoiding disadvantages for the patient, such as the need for retrospective implant removal. Additionally, the use of porogene additives in the suspension allows the creation of micro-level porosity in the ceramic implant. Furthermore, non-degradeable ceramics such as silicon nitride (SiAlON) and alumina-toughened zirconia (ATZ) are excellent materials for load-bearing applications. SiAlON typically combines high strengths, wear resistance, good antibacterial and osseointegration properties. It can be processed by LCM, resulting in identical properties as in conventional technologies. Characteristic strength of 760 MPa in a 4-point bending setup and densities above 99.9 % were achieved using LCM technology. Regarding ATZ, research in hot isostatic pressing resulted in excellent mechanical strength of 1650 MPa in a 4-point bending setup. Next to its high strength, it exhibits very good biocompatibility and easy processability, combining the best properties of zirconia and alumina. Freedom in design of LCM is accomplished by a wall thickness of 20 mm and densities above 99 %. Typical applications for these high performance ceramics are spinal implants and cranial implants for SiAlON or complex hip implants and thick-walled femoral heads for ATZ.
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