In surgical training, artificial bones are increasingly utilized for practicing operative techniques on osseous hard tissue. Advanced artificial training bones, adequately replicating the mechanical properties of natural bone, are being developed using additive manufacturing techniques such as Vat Photopolymerization (VPP) and Fused Deposition Modeling (FDM), followed by polymer infiltration. To mimic biomimetic structures, ceramic components with heterogeneous textures are fabricated through additive manufacturing processes. Shear forces during the forming process align the employed platelet-shaped, micron-scale particles, which are combined with spherical, submicron-scale particles. During sintering, anisotropic grain growth occurs (TGG technique), where larger anisotropic grains grow at the expense of smaller grains.

Subsequently, the hierarchically structured, porous ceramics are processed into hybrid materials through polymer infiltration. This method promises superior results compared to previous approaches using unfilled or homogeneously particle-filled polymers.

The artificial training bones produced by additive manufacturing and subsequent polymer infiltration are characterized in terms of their microstructure and mechanical properties. Particular emphasis is placed on replicating the hierarchical structure and associated mechanical properties of natural bones.

This innovative approach aims to overcome the limitations of current artificial bones, providing a more realistic training experience for surgeons. By closely mimicking the complex structure and mechanical behavior of natural bone, these advanced artificial bones have the potential to significantly enhance surgical education and skill development. The integration of cutting-edge manufacturing techniques with biomimetic design principles represents a promising attempt for creating next-generation training materials in the field of orthopedic and trauma surgery.