Ceramic additive manufacturing and microstructural analysis of tricalcium phosphate implants using X-ray microcomputed tomography

Additive manufacturing (AM) of ceramic bone implants from tricalcium phosphate (TCP) offers several benefits for bone regeneration and defect treatment. TCP scaffolds, e.g. featuring lattice or gyroid geometries, can effectively induce bone ingrowth and integration, showing a high potential in the treatment of large bone defects, e.g. as filler material for large bone defects. A major advantage of TCP is its osteoconductivity making it an effective choice for a broad range of orthopedic and dental applications. In addition, AM allows for the possibility to create precise, patient-specific implants with controllable mechanical properties. Those properties can be controlled by the implants' microstructure, e.g. in relation to bulk density and internal porosity. In this contribution, eleven resorbable bone implants were produced from 8-tricalcium phosphate (8-TCP) in order to quantify the internal porosity in three dimensions using microcomputed tomography (mu CT). All components were manufactured using an extrusion-based process and scanned using an industrial mu CT system at a voxel size of 10 mu m. Two samples were physically prepared to allow a high-resolution mu CT analysis at a voxel size of 1 mu m. Results show that post-processed image data enables the non-destructive inspection of highly complex ceramic AM implants. Using mu CT we were able to quantify internal porosity in 8-TCP bone implant and quantify the geometry and distribution of wall thicknesses in the gyroid geometry. However, a detailed microstructural analysis is only possible using high-resolution mu CT volume data, e.g. in relation to internal porosity. The findings emphasize that ceramic AM is able to produce complex components. However, NDT using mu CT is crucial in the development of new materials and geometries. mu CT provides high-resolution insights into the internal and external structure of ceramic AM components. It plays a critical role in detecting internal features, including small-scale porosity and delamination which are crucial for the integrity and functionality of medical implants. Moreover, mu CT provides volumetric data that supports the design and manufacturing process at various stages, enabling an iterative approach of continuous improvement in mechanical performance and osseointegration.