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The manufacture of PHBV and PHBV/Akermanite composite scaffolds using selective laser sintering

Authors: Sven Heinrich Diermann;

The manufacture of PHBV and PHBV/Akermanite composite scaffolds using selective laser sintering

Abstract

Autogenous (host), allogeneic (donor), or xenogeneic (animal donor) bone is conventionally used as a bone substitution material for the repair of fractured and defected bone. However, in autogenous bone grafting, it is necessary to undertake an additional harvesting surgery on the patient, and the supply of tissue is limited. For allogeneic and xenogeneic bone grafting, risks such as disease transfer and antigenic reactions exist. Three-dimensional (3D) matrices with an interconnected porous network, termed ‘scaffolds’, have the prospect to overcome the shortcomings related to current grafting techniques. Scaffolds do not carry the risk of transmitting diseases and are available in potentially endless amounts. Selective Laser Sintering (SLS) is a promising technique for the manufacture of scaffolds with customised shapes for bone tissue repair. However, the manufacture of scaffolds using SLS presents significant challenges, which has prevented the method from being used in a clinical setting. Engineering challenges include the SLS manufacture of scaffolds with appropriate mechanical properties, sufficiently small feature sizes and large specific surface areas, as well as reasonably good hydrophilic surface characteristics. Furthermore, previous research has focused on a limited variety of biomaterials, such as polycaprolactone (PCL) and PCL/ calcium phosphate composites. This is despite alternative materials, such as poly(3-hydroxybutyrateco-3-hydroxyvalerate) (PHBV) and Akermanite (AKM), having shown great promise for use in bone tissue repair. The objective of this thesis was therefore to develop novel bone tissue scaffolds fabricated via SLS, and made from PHBV as well as a PHBV/AKM composite. To achieve this, an SLS process was developed to synthesise PHBV scaffolds containing an interconnected pore network without requiring pre-designed porous architectures. To optimise the scaffold microstructure, the process parameters were systematically investigated. The final scaffolds had large specific surface areas and relative porosities of up to 80%. An increase in the laser energy density (LED) during fabrication led to the final scaffolds exhibiting higher relative densities, stronger inter-layer connections, and a reduced quantity of residual powder trapped inside the pores. An increase in relative density up to 41.1% resulted in a higher maximum compressive modulus and strength of 36.4 MPa and 6.7 MPa, respectively. The compressive deformation behaviour of the scaffolds differed depending on the loading direction as a consequence of their anisotropic microstructure. The behaviour could be understood by applying the concept of intra-layer-density-gradients. In vitro degradation of the manufactured PHBV scaffolds was investigated by their incubation in phosphate-buffered saline (PBS) solution for up to six weeks. The effect of incubation time on the molecular weight, crystallinity, mechanical properties, and weight loss of the PHBV scaffolds was systematically investigated. A substantial decrease in molecular weight and mechanical properties after incubation in combination with insignificant weight loss was associated with bulk degradation and erosion of the PHBV. All scaffolds maintained their microstructure after incubation. The scaffolds made using higher LEDs appeared to be more suitable for bone repair due to their superior mechanical properties after incubation. The use of AKM particles as a ceramic filler was investigated by their blending into PHBV powder and the subsequent SLS fabrication of novel composite scaffolds. The final PHBV/AKM scaffolds had a microstructure with an interconnected pore network, with large specific surface areas and pore sizes. Large amounts of AKM particles were exposed on the skeleton surface. All properties were highly favourable for bone tissue repair. AKM particles also reinforced the scaffold structure, leading to compressive moduli and strengths up to 103 MPa and 7.4 MPa, respectively; exceeding current benchmarks for SLS fabricated composite scaffolds with similar relative porosities. SLS was also used as a single-step process to manufacture hydrophilic PHBV and PHBV/AKM scaffolds, circumventing the need for post-processing. The inherent hydrophilicity resulted in excellent water uptake capabilities. Toluidine blue staining results indicated negatively charged skeleton surfaces in water. The hydrophilic surface of the scaffold was mainly attributed to the formation of carboxylic acid groups, introduced by thermal degradation of the PHBV during the SLS process. The manufactured scaffolds in this thesis present excellent potential for further in vivo testing due to their material composition, microstructure, in vitro degradation performance, mechanical properties, and surface properties; showing significant improvements in comparison to the state-of-the-art benchmarks for scaffolds with a pre-designed architecture manufactured using SLS.

Country
Australia
Related Organizations
Keywords

Selective Laser Sintering (SLS), Akermanite, Mechanical properties, Composite, Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), 0910 Manufacturing Engineering, Bone tissue engineering, Scaffold, Degradation, Surface modification, 0912 Materials Engineering, School of Mechanical and Mining Engineering, 0913 Mechanical Engineering

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selected citations
These citations are derived from selected sources.
This is an alternative to the "Influence" indicator, which also reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Citations provided by BIP!
popularity
This indicator reflects the "current" impact/attention (the "hype") of an article in the research community at large, based on the underlying citation network.
BIP!Popularity provided by BIP!
influence
This indicator reflects the overall/total impact of an article in the research community at large, based on the underlying citation network (diachronically).
BIP!Influence provided by BIP!
impulse
This indicator reflects the initial momentum of an article directly after its publication, based on the underlying citation network.
BIP!Impulse provided by BIP!
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