Individualized bone replacement parts by hybrid ceramic manufacturing

by Tassilo Moritz, Fraunhofer Institute for Ceramic Technologies and Systems IKTS

Recently, the innovative Freeze Foaming technique has been developed by Fraunhofer IKTS which allows producing an open cellular structure with a bimodal pore size distribution.

In in-vitro tests foams made of tricalciumphosphate and hydroxyapatite have been investigated with mice stem cells showing that the cells proliferate and start to differentiate and to form collagene structures. Now this method was combined with Vat Photo Polymerization (VPP) as an Additive Manufacturing technology for ceramic materials.

In this new hybrid process VPP offers the opportunity to build the cortical structure of an individualized bone replacement part whereas the spongious structure of the bone is formed by Freeze Foaming. During a subsequent common sintering step both structures are durably combined.

Hybrid manufacturing of bone-mimicking parts, basing on CAD data from real bones taken from rats, have been carried out. Segments of an artificial femur were tested in living animals. Testing results will be shown in the presentation.



What drives you?
Some years ago we invented the Freeze Foaming technology which allows mimicking of spongeous structures. Combined with Additive Manufacturing techniques new opportunities for making individualized bone replacement parts are now arising.

Why should the delegate attend your presentation?
The presentations shows a hybrid process of Lithography-based Ceramic Manufacturing and Freeze Foaming of hydrox apatite and TCP – a promising method for manufacturing of patient specific individualized bone replacement parts. Additive Manufacturing methods for ceramic components will be introduced and in-vitro such as in-vivo test results attained with mimicked rat bones will be shown.

About Tassilo Moritz

  • studies in the field of inorganic-nonmetallic materials at Freiberg University of Mining and Technology, Freiberg, Germany
  • working for Fraunhofer for 20 years
  • chairman of the Expert Group “Ceramic Injection Molding” in the German Ceramic Society
  • vice chairman of the “Scene Additive” in the German Ceramic Society

About Fraunhofer Institute for Ceramic Technologies and Systems IKTS

The Fraunhofer-Gesellschaft undertakes research for use by private and public enterprises and of benefit to society working on projects with applied research and demonstration activities for industrial applications.

Fraunhofer IKTS works on the development and application of modern high performance ceramic materials, industrial powder metallurgical technologies necessary to produce these materials and on the manufacturing of prototype components. The R&D process follows all the stages of product development, from production of the materials through development and optimization of the structure/property relationships to the application/system integration stage.

The working group “Shaping” deals with thermoplastic/plastic and suspension based shaping routes such as additive manufacturing for ceramic components. Specialized fields of the group are the development of novel shaping technologies by combining conventional processing routes or the combination of different materials in only one processing step for attaining multi-material and multifunctional applications. The equipment of the group spans the bridge between lab to pilot scale production.

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