EP2931326A1 - Bone substitute and method for producing same - Google Patents
Bone substitute and method for producing sameInfo
- Publication number
- EP2931326A1 EP2931326A1 EP12812816.2A EP12812816A EP2931326A1 EP 2931326 A1 EP2931326 A1 EP 2931326A1 EP 12812816 A EP12812816 A EP 12812816A EP 2931326 A1 EP2931326 A1 EP 2931326A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- bone substitute
- substitute according
- container
- jacket
- bone
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/28—Bones
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
- A61L27/02—Inorganic materials
- A61L27/12—Phosphorus-containing materials, e.g. apatite
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/3094—Designing or manufacturing processes
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2002/30001—Additional features of subject-matter classified in A61F2/28, A61F2/30 and subgroups thereof
- A61F2002/30003—Material related properties of the prosthesis or of a coating on the prosthesis
- A61F2002/30004—Material related properties of the prosthesis or of a coating on the prosthesis the prosthesis being made from materials having different values of a given property at different locations within the same prosthesis
- A61F2002/30011—Material related properties of the prosthesis or of a coating on the prosthesis the prosthesis being made from materials having different values of a given property at different locations within the same prosthesis differing in porosity
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2002/30001—Additional features of subject-matter classified in A61F2/28, A61F2/30 and subgroups thereof
- A61F2002/30108—Shapes
- A61F2002/30199—Three-dimensional shapes
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2002/30001—Additional features of subject-matter classified in A61F2/28, A61F2/30 and subgroups thereof
- A61F2002/30108—Shapes
- A61F2002/30199—Three-dimensional shapes
- A61F2002/30224—Three-dimensional shapes cylindrical
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2002/30001—Additional features of subject-matter classified in A61F2/28, A61F2/30 and subgroups thereof
- A61F2002/30316—The prosthesis having different structural features at different locations within the same prosthesis; Connections between prosthetic parts; Special structural features of bone or joint prostheses not otherwise provided for
- A61F2002/30535—Special structural features of bone or joint prostheses not otherwise provided for
- A61F2002/30581—Special structural features of bone or joint prostheses not otherwise provided for having a pocket filled with fluid, e.g. liquid
- A61F2002/30588—Special structural features of bone or joint prostheses not otherwise provided for having a pocket filled with fluid, e.g. liquid filled with solid particles
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/30767—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
- A61F2/30771—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth applied in original prostheses, e.g. holes or grooves
- A61F2002/30772—Apertures or holes, e.g. of circular cross section
- A61F2002/30784—Plurality of holes
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/3094—Designing or manufacturing processes
- A61F2002/30968—Sintering
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2210/00—Particular material properties of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
- A61F2210/0076—Particular material properties of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof multilayered, e.g. laminated structures
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2310/00—Prostheses classified in A61F2/28 or A61F2/30 - A61F2/44 being constructed from or coated with a particular material
- A61F2310/00005—The prosthesis being constructed from a particular material
- A61F2310/00179—Ceramics or ceramic-like structures
- A61F2310/00293—Ceramics or ceramic-like structures containing a phosphorus-containing compound, e.g. apatite
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L2430/00—Materials or treatment for tissue regeneration
- A61L2430/02—Materials or treatment for tissue regeneration for reconstruction of bones; weight-bearing implants
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/753—Medical equipment; Accessories therefor
- B29L2031/7532—Artificial members, protheses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
Definitions
- the invention relates to a bone substitute according to the preamble of claim 1 and to a method for its production according to the preamble of claim 29.
- the pore density or distribution within the bone substitute material is difficult to control. It would therefore be desirable to obtain a bone substitute in which the porosity, especially in the inner core of the scaffold or Scaffolds has a greater porosity than in the edge region.
- the porosity especially in the inner core of the scaffold or Scaffolds has a greater porosity than in the edge region.
- it is typically the other way round in the conventional methods, with the result that cell / scaffolding interactions concentrate on the periphery.
- the invention aims to remedy this situation.
- the invention has for its object to provide a bone substitute, which:
- a) also has a complex geometry with high porosity inside
- B) allows the migration of cells; c) has an optimal surface-to-volume ratio, with as large a volume as possible accessible to the bone cells being available per volume; d) has a strength which enables the typically necessary manipulation of the bone substitute without damage; e) requires very little or no polymer components;
- the invention solves this problem with a bone substitute, which has the features according to claim 1, and a method for its production, which has the features of claim 29.
- the container has one or more windows penetrating the jacket.
- the loose particles can thus be removed by depowdering through the window or windows from the cavity of the container.
- the dimensions of the individual packing are defined by their longest enveloping circular cylinder with the diameter D z .
- the average diameter Dp of the particles is between 1 pm and 250 pm.
- the mean diameter D M of the pores or channels is less than Dz.
- each of the windows has a smallest dimension DF that obeys the relationship D z >DF> Dp.
- the diameter Dz is greater than 200 pm, preferably greater than 500 pm.
- the diameter DF is greater than 50 pm.
- the filler body and the jacket are produced in one operation by means of a three-dimensional printing process 3DP or a selective laser sintering process SLS.
- the inventive bone substitute may also be made by making a hollow cylinder, filling the cylinder with small particles, and closing the ends of the cylinder with a hydraulic cement.
- the filler bodies are spaced apart, wherein preferably the minimum distance between the packing is greater than 50 pm. If the fillers are placed too close together, they may stick together.
- the jacket in addition to the openings and the windows, contains a number of passages whose diameter D D is at least equal to Dp and at least 30 ⁇ m. In a further embodiment, the jacket has interparticle and intercrystalline spaces with an average diameter which is in the range of 0.1 D P to 0.5 Dp and 1 to 50 ⁇ .
- the jacket of the container and the packing are the reaction product of the solidification of a loose powder of the particles, preferably produced by means of 3DP or SLS.
- solidification by crystal formation or polymerization e.g., sugar or salt powder + water from the printhead or, alternatively, any powder + salt / sugar / polymer solution from the printhead.
- the sugar crystals form a matrix which the CaP particles
- Sugar crystals include.
- Example Polymer solution printed on powder bed with any material.
- the jacket of the container and the packing are different reaction products of the solidification of a loose powder of the particles, preferably generated by means of 3DP or SLS.
- the 3DP process allows for different solutions (eg with two printheads) which potentially lead to different reaction products.
- CDHA calcium-deficient hydroxyapatite
- DPD dicalcium-phosphate
- the jacket of the container and the packing are the reaction product of a hydraulic cement after its curing, preferably generated by 3DP.
- the shell of the container and the packing are the melt product of the composite of a ceramic powder in a SLS process.
- the solidification is based on the reaction of one or more calcium phosphates or calcium sulphates with an aqueous solution.
- the calcium phosphate is alpha-TCP, beta-TCP, hydroxyapatite, TetCP or a mixture thereof.
- the final product contains DCPD, DCP or a mixture thereof.
- the solidification takes place on the reaction
- beta-TCP Ca 3 (PO 4 ) 2
- alpha-TCP Ca 3 (PO 4 ) 2
- hydroxyapatite Ca 5 (PO 4 ) 30H
- calcium-deficient hydroxyapatite Caio-x (HPO 4 ) x (P0 4 ) 6-x (OH) 2-x , with 0 ⁇ x 1) or tetracalcium phosphate (Ca 4 (PO 4 ) 2 0) and
- Additives to the aqueous liquid that are sprayed onto the powder bed by the printhead are acids, hydrogels, alcohols, fats, and surfactants.
- the advantage is achieved that the necessary for the solidification reaction acid is made possible by the MCPM cement reaction by pure water.
- much higher mechanical properties are achieved since it is not the capillary forces that determine the local cement reaction, but rather a more homogeneous one through the powder layer Reaction is enabled and thereby a better connection between the individual powder layers can be achieved.
- the porosity of the filling of the container defined by the filling bodies is in the range from 1 to 70%, preferably from 20 to 30%. This provides the advantage that the porosity between the packing aids the formation of cells and blood vessels.
- the fillers have pores with an average diameter of 1 pm to 50 pm.
- the sheath has any shape which is not rotationally symmetrical, but the sheath is preferably rotationally symmetrical.
- the jacket has a thickness d> Dz.
- the bone substitute comprises a plurality of interconnected containers, which are arranged side by side or one above the other.
- the bone substitute has, in addition to the plurality of unconnected packing, a number of interconnected packing.
- the jacket has one or more columnar protrusions projecting inside the container.
- the container has on the inside one or more transverse bars, which are connected at both ends with the jacket.
- the layers produced by the 3DP or SLS method have a thickness of from 10 pm to 250 pm, preferably from 30 pm to 100 pm.
- the particles of the hydraulic cement which form the powder consist of MCP and MCPM and TCP and are cured solely by means of water or aqueous solution.
- the loose particles remaining inside the container by the 3DP or SLS method are removed from the container by at least one window using one of the following techniques:
- the advantage is achieved that the remaining non-interconnected particles of the powder in the 3DP and SLS process form a kind of support function for overhanging and nested geometries of the container and the packing.
- This is a decisive advantage over other rapid prototyping methods.
- the disadvantage that the remaining particles must be removed again is overcome according to the invention.
- the small movements of the filling bodies and the time-dependent deflection and swirling of the injected air allow the depowdering even of complex geometries in the interior of the shell.
- a preferred use of the bone substitute is the in vivo colonization with body cells or in vitro culture of cell tissues.
- Another preferred use of bone replacement is the in vitro colonization of bone or cartilage cells.
- the bone substitute is used to fill or bridge defects or voids in the bone.
- the invention and further developments of the invention are explained in more detail below with reference to the partially schematic representations of several embodiments.
- Fig. 1 is a perspective view of an embodiment of the inventive bone replacement
- FIG. 2 shows a plan view of the embodiment of the bone replacement according to the invention shown in FIG. 1;
- FIG. 3 shows a longitudinal section through the embodiment of the inventive bone replacement shown in FIG. 1;
- FIG. 4 shows a cross section through the embodiment of the inventive bone replacement shown in FIG. 1;
- FIG. 5 shows a side view of the embodiment of the bone replacement according to the invention shown in FIG. 1;
- FIG. 6 shows a perspective view of a further embodiment of the bone substitute according to the invention.
- FIG. 7 shows a plan view of the embodiments of the bone replacement according to the invention shown in FIG. 6;
- FIG. 8 shows a longitudinal section through the embodiments of the inventive bone replacement shown in FIG. 6;
- FIG. 9 shows a cross section through the embodiment of the inventive bone replacement shown in FIG. 6; FIG. and
- FIG. 10 is a side view of the embodiment of the inventive bone replacement shown in FIG. 6.
- FIGS. 1 to 5 show an embodiment of the bone substitute 1 according to the invention, which essentially comprises a container 2 and a plurality of random packings 5 enclosed in the container 2.
- the dimensions of the individual packing 5 are defined by their longest enveloping circular cylinder with the diameter D z .
- the packing 5 consist of interconnected particles with a mean diameter Dp of at least 1 pm.
- the diameter D z of the longest wrapping body 5 enveloping Circular cylinder is greater than 200 ⁇ .
- the bone substitute 1 may comprise a plurality of interconnected container 2, which are arranged side by side or one above the other.
- the bone substitute 1 may comprise, in addition to the plurality of unconnected packing 5, a number of interconnected packing 5.
- the container 2 comprises a porous jacket 4 which is at least partially provided with openings (not shown) and which may have any desired shape, but is preferably rotationally symmetrical (eg hollow cylindrical).
- the container 2 further comprises a container bottom 7 and a container cover 8, wherein the container bottom 7 and the container cover 8 may also be porous and at least partially with openings (not shown) may be formed.
- the openings of the shell 4, the container bottom 7 and the container cover 8 are interconnected pores or channels with an average diameter of DM which is smaller than Dz.
- the container 2 comprises a plurality of the jacket 4 penetrating windows 6, which are dimensioned so that no filler 5 passes through one of the windows 6.
- the windows 6 have a smallest dimension D F , which obeys the relationship D z > D F > Dp.
- the diameter Dp of the window 6 is greater than about 50 ⁇ .
- the shell 4 may comprise a plurality of passages 3 (FIGS. 6 and 8 to 10) whose diameter DD corresponds at least to the mean diameter D P of the particles forming the packing 5, in order to remove the loose powder allow, but ideally greater than 30 ⁇ (angiogenesis) is.
- the jacket 4 may have interparticle and intergranular spaces, which have a mean diameter in the range of 0.1 Dp to 0.5 Dp, wherein this average diameter is between 1 and 50 ⁇ .
- the thickness d of the shell 4 may be smaller than the diameter Dz of the longest wrapping body 5 enveloping circular cylinder.
- the jacket 4 may have one or more columnar projections projecting inside the container 2.
- the container 2 inside one or more cross bars identify that are connected to both ends of the jacket 4.
- the porosity of the filling defined by the filling body 5 of the container 2 is in the range of 1 to 70%.
- SFF Solid Free Form Fabrication
- the present invention primarily relates to an application with the powder-based 3DP method (three-dimensional printing) but is also applicable to other powder-based SFF methods, such as e.g. SLS (Selective Laser Sintering) directly applicable.
- SFF Selective Laser Sintering
- 3D printers which include machines that build three-dimensional workpieces.
- the construction of the workpiece is usually computer-controlled from one or more liquid or powdery materials according to predetermined dimensions and shapes, which can be defined by CAD methods.
- the 3DP process is an additive process wherein a workpiece is made by sequentially forming layers of material.
- physical or chemical hardening processes take place.
- the dimensions and the shape are read in by the machine and then the individual layers of liquid, powder or plate-like material are deposited in succession, so that a workpiece is formed from a series of cross-sectional layers. These layers are automatically connected or fused together to make the workpiece.
- the SLS process is also an additive process whereby spatial structures are produced by sintering from a powdery starting material.
- the workpiece is also built up layer by layer, with small particles of plastic, metal or ceramic being melted by high-energy lasers (carbon dioxide lasers).
- the material is selectively melted on the surface of a powder bed to form a solid cross-sectional layer of the workpiece upon curing of the molten material.
- the powder bed is lowered by one layer thickness and a new layer of material is applied to the surface of the lowered powder bed. The process is repeated until the workpiece is completed.
- the jacket 4 of the container 2 and the plurality of random packings 5 are produced in layers at the same time by means of 3DP or SLS methods.
- the layers produced by the 3DP or SLS method may have a thickness of 10 pm to 250 pm, preferably of 30 pm -10 pm.
- the particles of the hydraulic cement constituting the powder may consist of MCPM (Ca (H 2 PO 4 ) 2 H 2 O) or MCP (Ca (H 2 PO 4 ) 2) and TCP and cured alone by means of an aqueous solution or water ,
- the uncured particles remaining inside the container by the 3DP or SLS method can be removed from the container 2 by at least one of the windows 6 using one of the following techniques: vacuum, rinsing with a medium in an ultrasonic bath, or vibration.
- Another innovation according to the invention relates to the composition of the powder.
- the prior art in 3DP for bone replacement is as follows: An acid is applied to the powder bed by means of a printhead, whereby the ceramic powder particles are locally bonded by means of a precipitation reaction.
- a novel method of blending the ceramic particles e.g., CaP calcium phosphates
- particles that form acid upon contact with water e.g., MCP monocalcium phosphate
- the bone substitute produced according to the invention is reinforced, for example, by immersion in an acid bath, by thermal aftertreatment, for example sintering or by aftertreatment (infiltration)
- post-hardening ie the bone substitute produced according to the invention is reinforced, for example, by immersion in an acid bath, by thermal aftertreatment, for example sintering or by aftertreatment (infiltration)
- a new and completely unproblematic "post-hardening” is possible by replacing the bone at a controlled or saturated humidity or by direct contact with water (with capillary Absorption, immersion or spraying) by subsequent crystal formation is solidified.
- the jacket 4 of the container 2 and the packing 5 may be the reaction product of the solidification of a loose powder of the particles and are produced by means of 3DP or SLS.
- Examples are a) solidification by crystal formation or polymerization (eg sugar or salt powder + water from the printhead or as another alternative any powder + salt / sugar / polymer solution from printhead (eg sugar / CaP powder bed locally with water droplets (from the printhead via 3DP The serrations of the sugar crystals form a matrix which holds the CaP particles together, and subsequent steps may involve further bonding of the CaP or washing out of the sugar crystals.)
- b) solidification by capillary forces: drying and dicing of the surface of a powder; c) solidification by gelation (eg alginate + Ca 2+ ions gel); d) solidification by cooling (eg a liquid medium is printed on a powder and solidifies on cooling); or e) solidification by sintering or melting and cooling (SLS or SLM (Selective
- the jacket 4 of the container 2 and the packing 5 may be the reaction product of a hydraulic cement after it has hardened, preferably produced by 3DP or else the reaction product of the composite of e.g. Be ceramic and polymer powder mixture in a SLS process.
- solidification may be based on the reaction of one or more calcium phosphates or calcium sulphates with an aqueous solution.
- the calcium phosphate may be alpha-TCP, beta-TCP, hydroxyapatite, TetCP or a mixture thereof.
- the solidification may also be based on the reaction a) of a powder mixture of MCP (Ca (H 2 PO 4 ) 2) or MCPM (Ca (H 2 PO 4 ) 2 H 2 O) or a mixture thereof with b) one or more several of the following substances: beta-TCP (Ca 3 (PO 4 ) 2) or, alpha-TCP (Ca 3 (PO 4 ) 2 ) or hydroxyapatite (Ca 5 (PO 4 ) 3 OH) or calcium-deficient hydroxyapatite (Caio -x (HPO 4 ) x (PO 4 ) 6-x (OH) 2-x , with 0 ⁇ x ⁇ 1) or tetracaicium phosphate (Ca 4 (PO 4 ) 2 0) and c) an aqueous solution or pure water respectively.
- beta-TCP Ca 3 (PO 4 ) 2
- alpha-TCP Ca 3 (PO 4 ) 2
- hydroxyapatite Ca 5
- the embodiment of the inventive bone replacement 1 shown in FIGS. 6 to 10 differs from the embodiment described in FIGS. 1 to 5 only in that the filling bodies 5 are T-shaped or mushroom-shaped.
- the filling bodies 5 may comprise two substantially circular-cylindrical sections, of which each a first section has a larger diameter than the second section adjoining thereto.
- Also differently configured embodiments of the packing 5 are conceivable and arbitrarily combinable.
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Abstract
Description
Knochenersatz und Verfahren zu dessen Herstellung Bone substitute and process for its preparation
Die Erfindung bezieht sich auf einen Knochenersatz gemäss dem Oberbegriff des Anspruchs 1 und auf ein Verfahren zu dessen Herstellung gemäss dem Oberbegriff des Patentanspruchs 29. The invention relates to a bone substitute according to the preamble of claim 1 and to a method for its production according to the preamble of claim 29.
Aus dem Stand der Technik sind für die Herstellung von Knochenersatzmaterialien konventionelle Herstellungsverfahren bekannt, die die Porosität und auch die Geometrie nicht vollständig kontrollieren können. Solche Herstellungsverfahren sind z.B. Templating, Emulsionsverfahren, lost wax method. Insbesondere die Geometrie lässt sich durch diese Verfahren typischerweise nur in einem beschränkten Bereich durch z.B. die Giessform bestimmen. Damit kann auch der äussere Rand der Geometrie aufgrund der geforderten Entformbarkeit nicht beliebig komplex sein. Insbesondere kann aber die Innengeometrie bzw. Architektur des Knochenersatzmaterials nur über die Porosität bestimmt werden. Diese ist durch die Geometrie und Anordnung der Porenfüller limitiert. Weiter werden für die Porenbildung Porenfüller gebraucht, die zu ungewünschten Interaktionen führen können. Typischerweise können nur kugelähnliche Poren hergestellt werden. Zu der limitierten Porengeometrie ist die Porendichte bzw. Verteilung innerhalb des Knochenersatzmaterials nur schwer zu kontrollieren. Wünschenswert wäre es deshalb einen Knochenersatz zu erhalten, bei dem die Porosität speziell im inneren Kern des Stützgerüsts oder Scaffolds eine grössere Porosität aufweist als im Randbereich. Typischerweise ist es bei den herkömmlichen Verfahren jedoch gerade umgekehrt, mit der Folge, dass sich Zell/Stützgerüst Interaktionen auf den Randbereich konzentrieren. From the state of the art, conventional manufacturing methods are known for the production of bone replacement materials, which can not completely control the porosity and also the geometry. Such production methods are e.g. Templating, emulsion method, lost wax method. In particular, the geometry can typically only be achieved in a limited range by e.g. determine the mold. Thus, the outer edge of the geometry can not be arbitrarily complex due to the required mold release. In particular, however, the internal geometry or architecture of the bone substitute material can only be determined via the porosity. This is limited by the geometry and arrangement of the pore filler. Furthermore, pore fillers are needed for pore formation, which can lead to undesired interactions. Typically, only spherical pores can be made. To the limited pore geometry, the pore density or distribution within the bone substitute material is difficult to control. It would therefore be desirable to obtain a bone substitute in which the porosity, especially in the inner core of the scaffold or Scaffolds has a greater porosity than in the edge region. However, it is typically the other way round in the conventional methods, with the result that cell / scaffolding interactions concentrate on the periphery.
Hier will die Erfindung Abhilfe schaffen. Der Erfindung liegt die Aufgabe zugrunde, einen Knochenersatz zu schaffen, welcher: The invention aims to remedy this situation. The invention has for its object to provide a bone substitute, which:
a) auch im Inneren eine komplexe Geometrie mit hoher Porosität aufweist; a) also has a complex geometry with high porosity inside;
(bei den bekannten Verfahren des Standes der Technik ist die Innengeometrie durch die Geometrie und Anordnung von Porenfüller nicht frei kontrollierbar. Bei den für das erfindungsgemäss Verfahren verwendeten herkömmlichen SFF-Methoden (Solid Freeform Fabrication) wie 3DP und SLS müssen im Innern Kanäle mit einer nicht frei wählbaren Geometrie erzeugt werden um ein Entfernen des losen Pulvers zu (In the known methods of the prior art, the internal geometry is not freely controllable by the geometry and arrangement of pore filler.) In the conventional SFF (Solid Freeform Fabrication) methods such as 3DP and SLS used in the process according to the invention, channels with one do not have to be inside freely selectable geometry can be generated to remove the loose powder
iestätigungsko ie ermöglichen. Die Erfindung will diesem Umstand Abhilfe schaffen und ermöglicht eine Innenarchitektur, die mit herkömmlichen SFF-Methoden nicht umsetzbar ist.) b) die Migration von Zellen erlaubt; c) ein optimales Verhältnis von Oberfläche zu Volumen aufweist, wobei pro Volumen eine möglichst grosse und für die Knochenzellen zugängliche Oberfläche zur Verfügung steht; d) eine Festigkeit aufweist, welche die typischerweise notwendigen Manipulation des Knochenersatzes ohne Beschädigung ermöglicht; e) mit sehr wenig oder gar keinen Polymeranteilen auskommt; iestätigungsko ie enable. The invention seeks to remedy this situation and allows an interior design that is not feasible with conventional SFF methods.) B) allows the migration of cells; c) has an optimal surface-to-volume ratio, with as large a volume as possible accessible to the bone cells being available per volume; d) has a strength which enables the typically necessary manipulation of the bone substitute without damage; e) requires very little or no polymer components;
(damit fallen keine toxischen Bestandteile, z.B. Reste von Monomeren und Vernetzer an, es erfolgt keine Degradation beim Sterilisieren, es werden problematische Abbauprodukte, wie z.B. Säuren vermieden und es erfolgt keine Reduktion der Abbaugeschwindigkeit.) f) ein einfaches „Depowdering" selbst von komplexen Geometrien im Inneren des Behälters durch die frei beweglichen Füllkörper gestattet; und g) einfach und kostengünstig in der Herstellung ist. (There are no toxic components, eg residues of monomers and crosslinkers, there is no degradation during sterilization, problematic degradation products, such as acids are avoided and there is no reduction in the rate of degradation.) f) a simple "depowdering" even of complex Geometries inside the container are allowed by the freely movable packing, and g) is simple and inexpensive to manufacture.
Die Erfindung löst die gestellte Aufgabe mit einem Knochenersatz, welcher die Merkmale gemäss Anspruch 1 aufweist, sowie einem Verfahren zu dessen Herstellung, welches die Merkmale des Anspruchs 29 aufweist. The invention solves this problem with a bone substitute, which has the features according to claim 1, and a method for its production, which has the features of claim 29.
Weitere vorteilhafte Ausgestaltungen der Erfindung können wie folgt kommentiert werden: Further advantageous embodiments of the invention can be commented on as follows:
In einer speziellen Ausführungsform weist der Behälter ein oder mehrere den Mantel durchdringende Fenster auf. Die losen Partikel können somit durch depowdering durch das oder die Fenster aus dem Hohlraum des Behälters entfernt werden. In einer anderen Ausführungsform sind die Abmessungen der einzelnen Füllkörper durch deren längsten umhüllenden Kreiszylinder mit dem Durchmesser Dz definiert. In a specific embodiment, the container has one or more windows penetrating the jacket. The loose particles can thus be removed by depowdering through the window or windows from the cavity of the container. In another embodiment, the dimensions of the individual packing are defined by their longest enveloping circular cylinder with the diameter D z .
In einer weiteren Ausführungsform beträgt der mittlere Durchmesser Dp der Partikel zwischen 1 pm und 250 pm. In a further embodiment, the average diameter Dp of the particles is between 1 pm and 250 pm.
In einer weiteren Ausführungsform ist der mittlere Durchmesser DM der Poren oder Kanäle kleiner als Dz. In a further embodiment, the mean diameter D M of the pores or channels is less than Dz.
In einer anderen Ausführungsform weist jedes der Fenster eine kleinste Dimension DF auf, welche der Beziehung Dz > DF > Dp gehorcht. In another embodiment, each of the windows has a smallest dimension DF that obeys the relationship D z >DF> Dp.
In wiederum einer anderen Ausführungsform ist der Durchmesser Dz grösser als 200 pm, vorzugsweise grösser als 500 pm. In yet another embodiment, the diameter Dz is greater than 200 pm, preferably greater than 500 pm.
In einer weiteren Ausführungsform ist der Durchmesser DF grösser als 50 pm. In a further embodiment, the diameter DF is greater than 50 pm.
In einer anderen Ausführungsform sind die Füllkörper sowie der Mantel in einem Arbeitsgang mittels eines dreidimensionalen Druckverfahrens 3DP oder eines Selektiven Laser-Sinter-Verfahrens SLS hergestellt. Alternativ kann der erfindungsgemässe Knochenersatz auch durch Herstellen eines hohlen Zylinders, Füllen des Zylinders mit kleinen Partikeln und Verschliessen der Enden des Zylinders mit einem hydraulischen Zement hergestellt werden. In another embodiment, the filler body and the jacket are produced in one operation by means of a three-dimensional printing process 3DP or a selective laser sintering process SLS. Alternatively, the inventive bone substitute may also be made by making a hollow cylinder, filling the cylinder with small particles, and closing the ends of the cylinder with a hydraulic cement.
In einer anderen Ausführungsform sind die Füllkörper voneinander beabstandet, wobei vorzugsweise der minimale Abstand zwischen den Füllkörpern grösser als 50 pm ist. Wenn die Füllkörper zu nah zusammen platziert werden, können diese miteinander verkleben. In another embodiment, the filler bodies are spaced apart, wherein preferably the minimum distance between the packing is greater than 50 pm. If the fillers are placed too close together, they may stick together.
In einer anderen Ausführungsform enthält der Mantel zusätzlich zu den Öffnungen und den Fenstern eine Anzahl von Durchgängen, deren Durchmesser DD mindestens gleich gross ist wie Dp und mindestens 30 pm beträgt. In einer weiteren Ausführungsform weist der Mantel interpartikuläre und interkristallinäre Zwischenräume auf mit einem mittleren Durchmesser, welcher im Bereich von 0,1 DP bis 0,5 Dp liegt und 1 bis 50 μητι beträgt. In another embodiment, in addition to the openings and the windows, the jacket contains a number of passages whose diameter D D is at least equal to Dp and at least 30 μm. In a further embodiment, the jacket has interparticle and intercrystalline spaces with an average diameter which is in the range of 0.1 D P to 0.5 Dp and 1 to 50 μητι.
In wiederum einer weiteren Ausführungsform sind der Mantel des Behälters und die Füllkörper das Reaktionsprodukt der Verfestigung eines losen Pulvers der Partikel, vorzugsweise mittels 3DP oder SLS erzeugt. In yet another embodiment, the jacket of the container and the packing are the reaction product of the solidification of a loose powder of the particles, preferably produced by means of 3DP or SLS.
Beispiele : Examples:
a) Verfestigung durch Kristallbildung oder Polymerisation (z.B. Zucker oder Salzpulver + Wasser aus dem Druckkopf oder als weitere Alternative beliebiges Pulver + Salz/Zucker/Polymerlösung aus dem Druckkopf). a) solidification by crystal formation or polymerization (e.g., sugar or salt powder + water from the printhead or, alternatively, any powder + salt / sugar / polymer solution from the printhead).
Beispiel: Zucker/CaP Pulverbett wird lokal mit Wassertropfen Example: Sugar / CaP powder bed becomes local with water drops
(aus dem Druckkopf via 3DP) besprüht. Die Verzahnungen (from the printhead via 3DP) sprayed. The gears
der Zuckerkristalle bilden eine Matrix welche die CaP Partikel The sugar crystals form a matrix which the CaP particles
zusammenhalten. Nachträgliche Schritte könnten einen stick together. Subsequent steps could be one
weiteren Verbund der CaP bzw. Auswaschen der further combination of CaP or washing out the
Zuckerkristalle beinhalten. Sugar crystals include.
b) Verfestigung durch Kapillarkräfte: Trocknen und Verzahnen der Oberfläche eines Pulvers; b) solidification by capillary forces: drying and dicing the surface of a powder;
c) Verfestigung durch Gelierung (z.B. Alginat + Ca2+ Ionen = Gel) c) solidification by gelation (eg alginate + Ca 2+ ions = gel)
Beispiel: Cellulosepulver wird durch eine geeignete aufgedruckte Lösung lokal gelöst und verfestigt; Example: Cellulose powder is locally dissolved and solidified by a suitable printed solution;
d) Verfestigung durch Abkühlen (z.B. ein flüssiges Medium wird auf ein Pulver gedruckt und verfestigt sich durch die Abkühlung); d) solidification by cooling (e.g., a liquid medium is printed on a powder and solidifies upon cooling);
Beispiel: Polymerlösung auf Pulverbett beliebiges Material aufgedruckt. Example: Polymer solution printed on powder bed with any material.
e) Verfestigung durch Sintern oder Schmelzen und Abkühlen (SLS oder SLM (Selective Laser Melting) Verfahren). e) Solidification by sintering or melting and cooling (SLS or SLM (Selective Laser Melting) method).
In einer anderen Ausführungsform sind der Mantel des Behälters und die Füllkörper unterschiedliche Reaktionsprodukte der Verfestigung eines losen Pulvers der Partikel, vorzugsweise mittels 3DP oder SLS erzeugt. Das 3DP-Verfahren ermöglicht unterschiedliche Lösungen (z.B. mit zwei Druckköpfen), welche potentiell zu unterschiedlichen Reaktionsprodukten führen. Beispielsweise kann durch drucken mit Wasser und Phosphorsäure und einem alpha-TCP entweder CDHA (Kalzium-defizitärer Hydroxyapatit) oder DPD (Monetit, Dicalcium-Phosphat) hergestellt werden. In another embodiment, the jacket of the container and the packing are different reaction products of the solidification of a loose powder of the particles, preferably generated by means of 3DP or SLS. The 3DP process allows for different solutions (eg with two printheads) which potentially lead to different reaction products. For example, by printing with Water and phosphoric acid and an alpha-TCP either CDHA (calcium-deficient hydroxyapatite) or DPD (monetit, dicalcium-phosphate).
In einer weiteren Ausführungsform sind der Mantel des Behälters und die Füllkörper das Reaktionsprodukt eines hydraulischen Zementes nach dessen Aushärtung, vorzugsweise durch 3DP erzeugt. In a further embodiment, the jacket of the container and the packing are the reaction product of a hydraulic cement after its curing, preferably generated by 3DP.
In wiederum einer weiteren Ausführungsform sind der Mantel des Behälters und die Füllkörper das Schmelzprodukt des Verbundes eines keramischen Pulvers in einem SLS Prozess. In yet another embodiment, the shell of the container and the packing are the melt product of the composite of a ceramic powder in a SLS process.
In einer anderen Ausführungsform basiert die Verfestigung auf der Reaktion eines oder mehrerer Kalziumphosphate oder Kalziumsulphate mit einer wässerigen Lösung. In another embodiment, the solidification is based on the reaction of one or more calcium phosphates or calcium sulphates with an aqueous solution.
In einer weiteren Ausführungsform ist das Kalziumphosphat das alpha-TCP, beta-TCP, Hydroxylapatit, TetCP oder eine Mischung davon. In another embodiment, the calcium phosphate is alpha-TCP, beta-TCP, hydroxyapatite, TetCP or a mixture thereof.
In wiederum einer weiteren Ausführungsform enthält das Endprodukt DCPD, DCP oder eine Mischung davon. In yet another embodiment, the final product contains DCPD, DCP or a mixture thereof.
In einer weiteren Ausführungsform erfolgt die Verfestigung auf der Reaktion In a further embodiment, the solidification takes place on the reaction
a) einer Pulvermischung von MCP (Ca(H2P04)2) oder MCPM (Ca(H2P04)2 H20) oder einer Mischung davon mit a) a powder mixture of MCP (Ca (H 2 PO 4 ) 2) or MCPM (Ca (H 2 PO 4 ) 2 H 2 O) or a mixture thereof with
b) einer oder mehreren der folgenden Substanzen: b) one or more of the following substances:
beta-TCP (Ca3(P04)2) oder , alpha-TCP(Ca3(P04)2) oder Hydroxyapatit (Ca5(P04)30H) oder Kalzium-defizitärem Hydroxyapatit (Caio-x(HP04)x(P04)6-x(OH)2-x, mit 0 ^ x 1) oder Tetracalcium Phosphat (Ca4(P04)20) und beta-TCP (Ca 3 (PO 4 ) 2 ) or, alpha-TCP (Ca 3 (PO 4 ) 2 ) or hydroxyapatite (Ca 5 (PO 4 ) 30H) or calcium-deficient hydroxyapatite (Caio-x (HPO 4 ) x (P0 4 ) 6-x (OH) 2-x , with 0 ^ x 1) or tetracalcium phosphate (Ca 4 (PO 4 ) 2 0) and
c) einer wässerigen Lösung oder reinem Wasser. c) an aqueous solution or pure water.
Zusätze zu der wässrigen Flüssigkeit, die durch den Druckkopf auf das Pulverbett aufgesprüht werden, sind Säuren, Hydrogele, Alkohole, Fette und Tenside. Damit ist der Vorteil erreichbar, dass die für die Verfestigungsreaktion nötige Säure durch die MCPM Zementreaktion durch reines Wasser ermöglicht wird. Dadurch werden wesentlich höhere mechanische Eigenschaften erzielt, da nicht die Kapillarkräfte die lokale Zementreaktion bestimmen sondern eine durch die Pulverschicht homogenere Reaktion ermöglicht wird und dadurch eine bessere Verbindung zwischen den einzelnen Pulverschichten erreichbar ist. Additives to the aqueous liquid that are sprayed onto the powder bed by the printhead are acids, hydrogels, alcohols, fats, and surfactants. Thus, the advantage is achieved that the necessary for the solidification reaction acid is made possible by the MCPM cement reaction by pure water. As a result, much higher mechanical properties are achieved since it is not the capillary forces that determine the local cement reaction, but rather a more homogeneous one through the powder layer Reaction is enabled and thereby a better connection between the individual powder layers can be achieved.
In einer anderen Ausführungsform liegt die Porosität der durch die Füllkörper definierten Füllung des Behälters im Bereich von 1 bis 70 %, vorzugsweise von 20 bis 30 %. Dies ermöglicht den Vorteil, dass die zwischen den Füllkörpern liegende Porosität die Bildung von Zellen und Blutgefässen begünstig. In another embodiment, the porosity of the filling of the container defined by the filling bodies is in the range from 1 to 70%, preferably from 20 to 30%. This provides the advantage that the porosity between the packing aids the formation of cells and blood vessels.
In einer anderen Ausführungsform weisen die Füllkörper Poren mit einem mittleren Durchmesser von 1 pm bis 50 pm auf. In another embodiment, the fillers have pores with an average diameter of 1 pm to 50 pm.
In wiederum einer anderen Ausführungsform weist der Mantel eine beliebige auch nicht rotationssymmetrische Form auf, vorzugsweise ist der Mantel jedoch rotationssymmetrisch ausgebildet. In yet another embodiment, the sheath has any shape which is not rotationally symmetrical, but the sheath is preferably rotationally symmetrical.
In einer weiteren Ausführungsform weist der Mantel eine Dicke d > Dz auf. In a further embodiment, the jacket has a thickness d> Dz.
In einer weiteren Ausführungsform umfasst der Knochenersatz mehrere miteinander verbundene Behälter, welche nebeneinander oder übereinander angeordnet sind. In a further embodiment, the bone substitute comprises a plurality of interconnected containers, which are arranged side by side or one above the other.
In einer anderen Ausführungsform weist der Knochenersatz zusätzlich zur Mehrzahl von nicht miteinander verbundenen Füllkörpern eine Anzahl untereinander verbundener Füllkörper auf. In another embodiment, the bone substitute has, in addition to the plurality of unconnected packing, a number of interconnected packing.
In wiederum einer anderen Ausführungsform weist der Mantel einen oder mehrere säulenartige ins Innere des Behälters ragende Vorsprünge auf. In yet another embodiment, the jacket has one or more columnar protrusions projecting inside the container.
In einer weiteren Ausführungsform weist der Behälter im Inneren einen oder mehrere Querbalken auf, die mit beiden ihrer Enden mit dem Mantel verbunden sind. In a further embodiment, the container has on the inside one or more transverse bars, which are connected at both ends with the jacket.
In einer speziellen Ausführungsform des Verfahrens weisen die durch das 3DP oder SLS Verfahrens erzeugten Schichten eine Dicke von 10 pm bis 250 pm, vorzugsweise von 30 pm -100 pm auf. In einer weiteren Ausführungsform des Verfahrens bestehen die das Pulver bildenden Partikel des hydraulischen Zementes aus MCP und MCPM und TCP und werden allein mittels Wasser oder wässriger Lösung ausgehärtet. Damit ist der Vorteil erreichbar, dass keine Phosphorsäure wie bei den anderen Calciumphosphaten notwendig ist. Damit werden die 3DP Druckköpfe (die üblicherweise nicht für Säuren ausgelegt sind) nicht nur geschont, sondern eine hohe Qualität wird ermöglicht, da der Druckkopf reproduzierbar arbeitet. Weiter kann so das Calcium/Phosphatverhältnis genau kontrolliert werden. In a specific embodiment of the method, the layers produced by the 3DP or SLS method have a thickness of from 10 pm to 250 pm, preferably from 30 pm to 100 pm. In a further embodiment of the method, the particles of the hydraulic cement which form the powder consist of MCP and MCPM and TCP and are cured solely by means of water or aqueous solution. Thus, the advantage is achieved that no phosphoric acid as in the other calcium phosphates is necessary. This not only protects the 3DP printheads (which are usually not designed for acids), but also ensures high quality because the printhead works reproducibly. Furthermore, the calcium / phosphate ratio can be precisely controlled.
In einer anderen Ausführungsform des Verfahrens werden die vom 3DP oder SLS Verfahren im Inneren des Behälters verbliebenen losen Partikel durch Anwendung einer der folgenden Techniken durch mindestens ein Fenster aus dem Behälter entfernt: In another embodiment of the method, the loose particles remaining inside the container by the 3DP or SLS method are removed from the container by at least one window using one of the following techniques:
Vakuum, Spülen mit einem Medium in einem Ultraschallbad oder Vibration. Vacuum, rinse with a medium in an ultrasonic bath or vibration.
Damit ist der Vorteil erreichbar, dass die verbleibenden nicht miteinander verbundenen Partikel des Pulvers beim 3DP und SLS Verfahren eine Art Stützfunktion auch für überhängende und verschachtelte Geometrien des Behälters und der Füllkörper bilden. Das ist ein entscheidender Vorteil gegenüber anderen Rapid Prototyping Verfahren. Der Nachteil, dass die verbleibenden Partikel wieder entfernt werden müssen wird erfindungsgemäss überwunden. Dabei ermöglichen die kleinen Bewegungen der Füllkörper und die damit zeitlich abhängige Umlenkung und Verwirbelung der eingeblasenen Luft das depowdering auch von komplexen Geometrien im Innern des Mantels. Thus, the advantage is achieved that the remaining non-interconnected particles of the powder in the 3DP and SLS process form a kind of support function for overhanging and nested geometries of the container and the packing. This is a decisive advantage over other rapid prototyping methods. The disadvantage that the remaining particles must be removed again is overcome according to the invention. The small movements of the filling bodies and the time-dependent deflection and swirling of the injected air allow the depowdering even of complex geometries in the interior of the shell.
Eine bevorzugte Verwendung des Knochenersatzes ist die in vivo Besiedelung mit Körperzellen oder in vitro Züchtung von Zellgeweben. A preferred use of the bone substitute is the in vivo colonization with body cells or in vitro culture of cell tissues.
Eine weitere bevorzugte Verwendung des Knochenersatzes ist die in-vitro Besiedelung von Knochen- oder Knorpelzellen. Another preferred use of bone replacement is the in vitro colonization of bone or cartilage cells.
Vorzugsweise wird der Knochenersatz zum Füllen oder Überbrücken von Defekten oder Hohlräumen im Knochen verwendet. Die Erfindung und Weiterbildungen der Erfindung werden im Folgenden anhand der teilweise schematischen Darstellungen mehrerer Ausführungsbeispiele noch näher erläutert. Preferably, the bone substitute is used to fill or bridge defects or voids in the bone. The invention and further developments of the invention are explained in more detail below with reference to the partially schematic representations of several embodiments.
Es zeigen: Show it:
Fig. 1 eine perspektivische Ansicht einer Ausführungsform des erfindungsgemässen Knochenersatzes; Fig. 1 is a perspective view of an embodiment of the inventive bone replacement;
Fig. 2 eine Aufsicht auf die in Fig. 1 dargestellte Ausführungsform des erfindungsgemässen Knochenersatzes; FIG. 2 shows a plan view of the embodiment of the bone replacement according to the invention shown in FIG. 1; FIG.
Fig. 3 einen Längsschnitt durch die in Fig. 1 dargestellte Ausführungsform des erfindungsgemässen Knochenersatzes; 3 shows a longitudinal section through the embodiment of the inventive bone replacement shown in FIG. 1; FIG.
Fig. 4 einen Querschnitt durch die in Fig. 1 dargestellte Ausführungsform des erfindungsgemässen Knochenersatzes; 4 shows a cross section through the embodiment of the inventive bone replacement shown in FIG. 1; FIG.
Fig. 5 eine Seitenansicht der in Fig. 1 dargestellten Ausführungsform des erfindungsgemässen Knochenersatzes; FIG. 5 shows a side view of the embodiment of the bone replacement according to the invention shown in FIG. 1; FIG.
Fig. 6 eine perspektivische Ansicht einer weiteren Ausführungsform des erfindungsgemässen Knochenersatzes; 6 shows a perspective view of a further embodiment of the bone substitute according to the invention;
Fig. 7 eine Aufsicht auf die in Fig. 6 dargestellte Ausführungsformen des erfindungsgemässen Knochenersatzes; FIG. 7 shows a plan view of the embodiments of the bone replacement according to the invention shown in FIG. 6; FIG.
Fig. 8 einen Längsschnitt durch die in Fig. 6 dargestellte Ausführungsformen des erfindungsgemässen Knochenersatzes; 8 shows a longitudinal section through the embodiments of the inventive bone replacement shown in FIG. 6; FIG.
Fig. 9 einen Querschnitt durch die in Fig. 6 dargestellte Ausführungsform des erfindungsgemässen Knochenersatzes; und 9 shows a cross section through the embodiment of the inventive bone replacement shown in FIG. 6; FIG. and
Fig. 10 eine Seitenansicht der in Fig. 6 dargestellten Ausführungsform des erfindungsgemässen Knochenersatzes. 10 is a side view of the embodiment of the inventive bone replacement shown in FIG. 6.
In den Figuren 1 bis 5 ist eine Ausführungsform des erfindungsgemässen Knochenersatzes 1 dargestellt, welche im Wesentlichen einen Behälter 2 und eine Mehrzahl von im Behälter 2 eingeschlossenen Füllkörpern 5 umfasst. Die Abmessungen der einzelnen Füllkörper 5 sind durch deren längsten umhüllenden Kreiszylinder mit dem Durchmesser Dz definiert. Die Füllkörper 5 bestehen aus miteinander verbundenen Partikeln mit einem mittleren Durchmesser Dp von mindestens 1 pm. Der Durchmesser Dz des längsten einen Füllkörper 5 umhüllenden Kreiszylinders ist grösser als 200 μητι. Der Knochenersatz 1 kann mehrere miteinander verbundene Behälter 2 umfassen, welche nebeneinander oder übereinander angeordnet sind. Ferner kann der Knochenersatz 1 zusätzlich zur Mehrzahl von nicht miteinander verbundenen Füllkörpern 5 eine Anzahl untereinander verbundener Füllkörper 5 umfassen. FIGS. 1 to 5 show an embodiment of the bone substitute 1 according to the invention, which essentially comprises a container 2 and a plurality of random packings 5 enclosed in the container 2. The dimensions of the individual packing 5 are defined by their longest enveloping circular cylinder with the diameter D z . The packing 5 consist of interconnected particles with a mean diameter Dp of at least 1 pm. The diameter D z of the longest wrapping body 5 enveloping Circular cylinder is greater than 200 μητι. The bone substitute 1 may comprise a plurality of interconnected container 2, which are arranged side by side or one above the other. Furthermore, the bone substitute 1 may comprise, in addition to the plurality of unconnected packing 5, a number of interconnected packing 5.
Der Behälter 2 umfasst einen porösen und mindestens teilweise mit Öffnungen (nicht gezeichnet) versehenen Mantel 4, welcher jede beliebige Form aufweisen kann aber vorzugsweise rotationssymmetrisch (z.B. hohlzylindrisch) ausgebildet ist. Der Behälter 2 weist ferner einen Behälterboden 7 und eine Behälterdecke 8 auf, wobei der Behälterboden 7 und die Behälterdecke 8 ebenfalls porös und mindestens teilweise mit Öffnungen (nicht gezeichnet) ausgebildet sein können. Die Öffnungen des Mantels 4, des Behälterbodens 7 und der Behälterdecke 8 sind untereinander verbundene Poren oder Kanäle mit einem mittleren Durchmesser von DM, welcher kleiner als Dz ist. Ferner umfasst der Behälter 2 eine Mehrzahl von den Mantel 4 durchdringenden Fenstern 6, die so bemessen sind, dass kein Füllkörper 5 durch eines der Fenster 6 hindurchgeht. Dazu weisen die Fenster 6 eine kleinste Dimension DF auf, welche der Beziehung Dz > DF > Dp gehorcht. Der Durchmesser Dp der Fenster 6 ist grösser als ungefähr 50 μιτι. The container 2 comprises a porous jacket 4 which is at least partially provided with openings (not shown) and which may have any desired shape, but is preferably rotationally symmetrical (eg hollow cylindrical). The container 2 further comprises a container bottom 7 and a container cover 8, wherein the container bottom 7 and the container cover 8 may also be porous and at least partially with openings (not shown) may be formed. The openings of the shell 4, the container bottom 7 and the container cover 8 are interconnected pores or channels with an average diameter of DM which is smaller than Dz. Further, the container 2 comprises a plurality of the jacket 4 penetrating windows 6, which are dimensioned so that no filler 5 passes through one of the windows 6. For this purpose, the windows 6 have a smallest dimension D F , which obeys the relationship D z > D F > Dp. The diameter Dp of the window 6 is greater than about 50 μιτι.
Ferner kann der Mantel 4 zusätzlich zu den Öffnungen und den Fenstern 6 mehrere Durchgänge 3 (Figuren 6 und 8 bis 10) umfassen, deren Durchmesser DD mindestens dem mittleren Durchmesser DP der die Füllkörper 5 bildenden Partikel entspricht, um ein Entfernen des losen Pulvers zu ermöglichen, jedoch idealerweise grösser als 30 μιτι (Angiogenesis) ist. Der Mantel 4 kann interpartikuläre und interkristalline Zwischenräume aufweisen, welche einen mittleren Durchmesser im Bereich von 0,1 Dp bis 0,5 Dp aufweisen, wobei dieser mittlere Durchmesser zwischen 1 und 50 μιτι beträgt. Die Dicke d des Mantels 4 kann kleiner als der Durchmesser Dz der längsten die Füllkörper 5 umhüllenden Kreiszylinder sein. Der Mantel 4 kann einen oder mehrere säulenartige ins Innere des Behälters 2 ragende Vorsprünge aufweisen. Zudem oder alternativ dazu kann der Behälter 2 im Inneren einen oder mehrere Querbalken ausweisen, die mit beiden ihrer Enden mit dem Mantel 4 verbunden sind. Die Porosität der durch die Füllkörper 5 definierten Füllung des Behälters 2 liegt im Bereich von 1 bis 70 %. Die Füllkörper 5 sind beispielsweise, aber nicht beschränkt auf, kugelförmig ausgebildet und können Poren mit einem mittleren Durchmesser von 1 μιη bis 50 pm aufweisen. Further, in addition to the openings and the windows 6, the shell 4 may comprise a plurality of passages 3 (FIGS. 6 and 8 to 10) whose diameter DD corresponds at least to the mean diameter D P of the particles forming the packing 5, in order to remove the loose powder allow, but ideally greater than 30 μιτι (angiogenesis) is. The jacket 4 may have interparticle and intergranular spaces, which have a mean diameter in the range of 0.1 Dp to 0.5 Dp, wherein this average diameter is between 1 and 50 μιτι. The thickness d of the shell 4 may be smaller than the diameter Dz of the longest wrapping body 5 enveloping circular cylinder. The jacket 4 may have one or more columnar projections projecting inside the container 2. In addition, or alternatively, the container 2 inside one or more cross bars identify that are connected to both ends of the jacket 4. The porosity of the filling defined by the filling body 5 of the container 2 is in the range of 1 to 70%. The packing 5, for example, but not limited to, spherical formed and may have pores with a mean diameter of 1 μιη to 50 pm.
Neben den konventionellen Herstellungsverfahren sind sogenannte SFF-Verfahren (Solid Free Form Fabrication) zur Herstellung von Knochenersatzmaterialien bekannt. Die Geometrie ist bei diesen sogenannten SFF-Verfahren frei definierbar. In addition to the conventional manufacturing processes so-called SFF (Solid Free Form Fabrication) methods for the production of bone replacement materials are known. The geometry is freely definable in these so-called SFF methods.
Die vorliegende Erfindung bezieht sich primär auf eine Anwendung mit dem pulverbasierten 3DP-Verfahren (Three-Dimensional Printing) ist jedoch auch auf andere pulverbasierte SFF-Verfahren wie z.B. SLS (Selective Laser Sintering) direkt anwendbar. However, the present invention primarily relates to an application with the powder-based 3DP method (three-dimensional printing) but is also applicable to other powder-based SFF methods, such as e.g. SLS (Selective Laser Sintering) directly applicable.
Beim 3DP-Verfahren werden sogenannte 3D-Drucker verwendet, welche Maschinen umfassen, die dreidimensionale Werkstücke aufbauen. Der Aufbau des Werkstücks erfolgt üblicherweise computergesteuert aus einem oder mehreren flüssigen oder pulverförmigen Werkstoffen nach vorgegebenen Abmessungen und Formen, welche durch CAD-Verfahren definiert werden können. Das 3DP-Verfahren ist ein additives Verfahren, wobei ein Werkstück durch ein aufeinanderfolgendes Bilden von Materialschichten hergestellt wird. Daneben finden beim Aufbau des Werkstücks physikalische oder chemische Härtungsprozesse statt. Zur Herstellung des Werkstücks werden die Abmessungen und die Form durch die Maschine eingelesen und anschliessend werden nacheinander die einzelnen Schichten aus Flüssigkeit, Pulver oder plattenartigem Material deponiert, so dass ein Werkstück aus einer Reihe von Querschnittsschichten gebildet wird. Diese Schichten werden zur Herstellung des Werkstücks automatisch miteinander verbunden oder fusioniert. In the 3DP process so-called 3D printers are used, which include machines that build three-dimensional workpieces. The construction of the workpiece is usually computer-controlled from one or more liquid or powdery materials according to predetermined dimensions and shapes, which can be defined by CAD methods. The 3DP process is an additive process wherein a workpiece is made by sequentially forming layers of material. In addition, during the construction of the workpiece, physical or chemical hardening processes take place. For the production of the workpiece, the dimensions and the shape are read in by the machine and then the individual layers of liquid, powder or plate-like material are deposited in succession, so that a workpiece is formed from a series of cross-sectional layers. These layers are automatically connected or fused together to make the workpiece.
Das SLS-Verfahren ist ebenfalls ein additives Verfahren, wobei räumliche Strukturen durch Sintern aus einem pulverförmigen Ausgangsmaterial hergestellt werden. Das Werkstück wird ebenfalls Schicht für Schicht aufgebaut, wobei durch Hochenergielaser (Kohlenstoffdioxidlaser) kleine Partikel aus Kunststoff, Metall oder Keramik geschmolzen werden. Das Material wird auf der Oberfläche eines Pulverbetts selektiv geschmolzen, so dass nach Aushärtung des geschmolzenen Materials eine feste Querschnittsschicht des Werkstücks gebildet wird. Nachdem eine Schicht fertiggestellt ist, wird das Pulverbett um eine Schichtdicke abgesenkt und eine neue Materialschicht wird auf die Oberfläche des abgesenkten Pulverbetts aufgetragen. Der Vorgang wird solange wiederholt bis das Werkstück fertiggestellt ist. The SLS process is also an additive process whereby spatial structures are produced by sintering from a powdery starting material. The workpiece is also built up layer by layer, with small particles of plastic, metal or ceramic being melted by high-energy lasers (carbon dioxide lasers). The material is selectively melted on the surface of a powder bed to form a solid cross-sectional layer of the workpiece upon curing of the molten material. After a layer is completed, the powder bed is lowered by one layer thickness and a new layer of material is applied to the surface of the lowered powder bed. The process is repeated until the workpiece is completed.
In einer Ausführungsform des erfindungsgemässen Verfahrens zur Herstellung des Knochenersatzes 1 werden der Mantel 4 des Behälters 2 und die Mehrzahl von Füllkörpern 5 gleichzeitig mittels 3DP- oder SLS Verfahren schichtweise hergestellt. Die durch das 3DP oder SLS Verfahrens erzeugten Schichten können eine Dicke von 10 pm bis 250 pm, vorzugsweise von 30 pm -10 pm aufweisen. Ferner können die das Pulver bildenden Partikel des hydraulischen Zementes aus MCPM (Ca(H2PO4)2 H2O) oder MCP (Ca(H2PO4)2) und TCP bestehen und allein mittels einer wässrigen Lösung oder Wasser ausgehärtet werden. Die vom 3DP oder SLS Verfahren im Inneren des Behälters verbliebenen nicht ausgehärteten Partikel können durch Anwendung einer der folgenden Techniken durch mindestens eines der Fenster 6 aus dem Behälter 2 entfernt werden: Vakuum, Spülen mit einem Medium in einem Ultraschallbad oder Vibration. In one embodiment of the method according to the invention for the production of the bone substitute 1, the jacket 4 of the container 2 and the plurality of random packings 5 are produced in layers at the same time by means of 3DP or SLS methods. The layers produced by the 3DP or SLS method may have a thickness of 10 pm to 250 pm, preferably of 30 pm -10 pm. Further, the particles of the hydraulic cement constituting the powder may consist of MCPM (Ca (H 2 PO 4 ) 2 H 2 O) or MCP (Ca (H 2 PO 4 ) 2) and TCP and cured alone by means of an aqueous solution or water , The uncured particles remaining inside the container by the 3DP or SLS method can be removed from the container 2 by at least one of the windows 6 using one of the following techniques: vacuum, rinsing with a medium in an ultrasonic bath, or vibration.
Im Folgenden wird der Einfachheit halber nur das 3DP-Verfahren erwähnt. Es sollen damit jedoch auch alternative Verfahren impliziert werden. Obwohl die Geometrie mit diesen Verfahren frei definierbar ist, müssen hinterschnittene und überhängende und verschachtelte Geometrien gestützt werden, da der Aufbau schichtweise erfolgt. Dies wiederum bedingt ein nachträgliches Entfernen dieser Stützen. Im Falle von 3DP und SLS wird die Stützfunktion durch loses Pulver übernommen, das später wieder entfernt werden muss (depowdering). Heute wird dies standardmässig bei mit 3DP und SLS hergestellten Teilen mit Luftdruck getan. Dazu wird eine Airbrush Düse verwendet, die gefilterte Druckluft auf den erfindungsgemäss hergestellten Knochenersatz bläst. Dadurch wird von Aussen her der erfindungsgemäss hergestellte Knochenersatz Schritt für Schritt von losen Partikeln des verwendeten Pulvers befreit. Insbesondere im Innern des erfindungsgemäss hergestellten Knochenersatzes bietet dies Schwierigkeiten. Deshalb ist bei SFF Methoden die Geometriefreiheit im Innern durch die Freiheit der Entfernung des freien Pulvers eingeschränkt. Kann das verbleibende nicht ausgehärtete Pulver nicht entfernt werden ist die Geometrie verloren. In der Praxis ist damit die Wahl der Geometrie speziell im Innern eines Körpers stark eingeschränkt. Typischerweise müssen grosse Kanäle gebaut werden, die ein „depowdering" ermöglichen. Die vorliegende Erfindung richtet sich schwergewichtig auf eine bessere Lösung für das„depowdering", die dadurch einen neuartigen Knochenersatz ermöglicht. Zudem erlaubt dieses Verfahren eine effiziente und wirtschaftliche Herstellung. In the following, for the sake of simplicity, only the 3DP method will be mentioned. However, alternative methods should also be implied. Although the geometry can be freely defined with these methods, undercut and overhanging and interlaced geometries must be supported, since the structure is layered. This in turn requires a subsequent removal of these supports. In the case of 3DP and SLS, the support function is taken over by loose powder, which later has to be removed again (depowdering). Today, this is done by default for parts manufactured with 3DP and SLS with air pressure. For this purpose, an airbrush nozzle is used which blows filtered compressed air onto the bone substitute produced according to the invention. As a result, the bone substitute produced according to the invention is freed step by step from loose particles of the powder used from the outside. In particular, in the interior of the bone substitute produced according to the invention this presents difficulties. Therefore, in SFF methods, the geometry freedom inside is limited by the freedom of removal of the free powder. If the remaining uncured powder can not be removed, the geometry is lost. In practice, the choice of geometry, especially in the interior of a body is severely limited. Typically, large channels must be built to allow for "depowdering." The present invention focuses heavily on a better one Solution for "depowdering", which allows a novel bone substitute, and allows efficient and economical production.
Eine weitere erfindungsgemässe Neuigkeit betrifft die Zusammensetzung des Pulvers. Stand der Technik im 3DP für Knochenersatz ist der folgende: Eine Säure wird mittels Druckkopf auf das Pulverbett aufgebracht, wodurch die keramischen Pulverpartikel lokal mittels einer Ausfällungsreaktion verbunden werden. Eine neuartige Methode durch Vermischung der keramischen Partikel (z.B. CaP Kalziumphosphate) mit Partikeln die bei Kontakt mit Wasser Säure bilden (z.B. MCP Monocalcium Phosphat) erlauben ein Drucken mit Wasser. Dies bietet neben der präzisen Einstellung des Kalzium/Phosphat- Verhältnisses noch weitere im Folgenden beschriebene Vorteile betreffend der mechanischen Eigenschaften und des Herstellungsverfahrens. Eine Möglichkeit die mechanischen Eigenschaften des erfindungsgemäss hergestellten Knochenersatzes weiter zu verbessern liegt in sog.„post-hardening" Schritten, d.h. der erfindungsgemäss hergestellte Knochenersatz wird z.B. durch Eintauchen in ein Säurebad, durch thermische Nachbehandlung z.B. Sintern oder durch ehem. Nachbehandlung (Infiltration) verstärkt. Im Falle des neuartigen Drucks mit einer wasserbasierten und säurefreien Lösung auf ein CaP/MCP Pulverbett ist somit ein neues und völlig unproblematisches „post-hardening" möglich, indem der Knochenersatz bei einer kontrollierten oder gesättigten Luftfeuchtigkeit oder durch direkten Kontakt mit Wasser (mit kapillarem Aufsaugen, Eintauchen oder Einsprühen) durch nachträgliche Kristallbildung verfestigt wird. Another innovation according to the invention relates to the composition of the powder. The prior art in 3DP for bone replacement is as follows: An acid is applied to the powder bed by means of a printhead, whereby the ceramic powder particles are locally bonded by means of a precipitation reaction. A novel method of blending the ceramic particles (e.g., CaP calcium phosphates) with particles that form acid upon contact with water (e.g., MCP monocalcium phosphate) allows printing with water. This offers, in addition to the precise adjustment of the calcium / phosphate ratio, further advantages described below regarding the mechanical properties and the production process. One possibility for further improving the mechanical properties of the bone substitute produced according to the invention lies in so-called "post-hardening" steps, ie the bone substitute produced according to the invention is reinforced, for example, by immersion in an acid bath, by thermal aftertreatment, for example sintering or by aftertreatment (infiltration) In the case of the novel pressure with a water-based and acid-free solution on a CaP / MCP powder bed, a new and completely unproblematic "post-hardening" is possible by replacing the bone at a controlled or saturated humidity or by direct contact with water (with capillary Absorption, immersion or spraying) by subsequent crystal formation is solidified.
Der Mantel 4 des Behälters 2 und die Füllkörper 5 können das Reaktionsprodukt der Verfestigung eines losen Pulvers der Partikel sein und werden mittels 3DP oder SLS erzeugt. Beispiele dafür sind a) Verfestigung durch Kristallbildung oder Polymerisation (z.B. Zucker oder Salzpulver + Wasser aus dem Druckkopf oder als weitere Alternative beliebiges Pulver + Salz/Zucker/Polymerlösung aus Druckkopf (Z.B. kann Zucker/CaP Pulverbett lokal mit Wassertropfen (aus dem Druckkopf via 3DP) besprüht werden. Die Verzahnungen der Zuckerkristalle bilden eine Matrix welche die CaP Partikel zusammenhalten. Nachträgliche Schritte könnten weiteren Verbund der CaP bzw. Auswaschen der Zuckerkristalle beinhalten); b) Verfestigung durch Kapillarkräfte: Trocknen und Verzahnen der Oberfläche eines Pulvers; c) Verfestigung durch Gelierung (z.B. Alginat + Ca2+ Ionen = Gel); d) Verfestigung durch Abkühlen (z.B. ein flüssiges Medium wird auf ein Pulver gedruckt und verfestigt sich durch die Abkühlung); oder e) Verfestigung durch Sintern oder Schmelzen und Abkühlen (SLS oder SLM (Selective Laser Melting) Verfahren. The jacket 4 of the container 2 and the packing 5 may be the reaction product of the solidification of a loose powder of the particles and are produced by means of 3DP or SLS. Examples are a) solidification by crystal formation or polymerization (eg sugar or salt powder + water from the printhead or as another alternative any powder + salt / sugar / polymer solution from printhead (eg sugar / CaP powder bed locally with water droplets (from the printhead via 3DP The serrations of the sugar crystals form a matrix which holds the CaP particles together, and subsequent steps may involve further bonding of the CaP or washing out of the sugar crystals.) b) solidification by capillary forces: drying and dicing of the surface of a powder; c) solidification by gelation (eg alginate + Ca 2+ ions = gel); d) solidification by cooling (eg a liquid medium is printed on a powder and solidifies on cooling); or e) solidification by sintering or melting and cooling (SLS or SLM (Selective Laser Melting) method.
Alternativ können der Mantel 4 des Behälters 2 und die Füllkörper 5 das Reaktionsprodukt eines hydraulischen Zementes nach dessen Aushärtung sein, vorzugsweise durch 3DP erzeugt oder aber auch das Reaktionsprodukt des Verbundes eines z.B. Keramik und Polymerpulvergemisches in einem SLS Prozess sein. Alternatively, the jacket 4 of the container 2 and the packing 5 may be the reaction product of a hydraulic cement after it has hardened, preferably produced by 3DP or else the reaction product of the composite of e.g. Be ceramic and polymer powder mixture in a SLS process.
Ferner kann die Verfestigung auf der Reaktion eines oder mehrerer Kalziumphosphate oder Kalziumsulphate mit einer wässerigen Lösung basieren. Dabei kann das Kalziumphosphat alpha-TCP, beta-TCP, Hydroxylapatit, TetCP oder eine Mischung davon sein. Further, solidification may be based on the reaction of one or more calcium phosphates or calcium sulphates with an aqueous solution. Here, the calcium phosphate may be alpha-TCP, beta-TCP, hydroxyapatite, TetCP or a mixture thereof.
Die Verfestigung kann in alternativen Ausführungsformen auch auf der Reaktion a) einer Pulvermischung von MCP (Ca(H2P04)2) oder MCPM (Ca(H2P04)2 H20) oder einer Mischung davon mit b) einer oder mehreren der folgenden Substanzen: beta-TCP (Ca3(P04)2) oder , alpha-TCP(Ca3(P04)2) oder Hydroxyapatit (Ca5(P04)3OH) oder Kalzium-defizitärem Hydroxyapatit (Caio-x(HP04)x(P04)6-x(OH)2-x, mit 0 < x < 1) oder Tetracaicium Phosphat (Ca4(P04)20) und c) einer wässerigen Lösung oder reinem Wasser erfolgen. In alternative embodiments, the solidification may also be based on the reaction a) of a powder mixture of MCP (Ca (H 2 PO 4 ) 2) or MCPM (Ca (H 2 PO 4 ) 2 H 2 O) or a mixture thereof with b) one or more several of the following substances: beta-TCP (Ca 3 (PO 4 ) 2) or, alpha-TCP (Ca 3 (PO 4 ) 2 ) or hydroxyapatite (Ca 5 (PO 4 ) 3 OH) or calcium-deficient hydroxyapatite (Caio -x (HPO 4 ) x (PO 4 ) 6-x (OH) 2-x , with 0 <x <1) or tetracaicium phosphate (Ca 4 (PO 4 ) 2 0) and c) an aqueous solution or pure water respectively.
Die in den Figuren 6 bis 10 dargestellte Ausführungsform des erfindungsgemässen Knochenersatzes 1 unterscheidet sich von der in den Fig. 1 bis 5 beschriebenen Ausführungsform nur darin, dass die Füllkörper 5 T-förmig oder pilzförmig ausgebildet sind. Dabei können die Füllkörper 5 zwei im Wesentlichen kreiszylindrische Abschnitte aufweisen, wovon je ein erster Abschnitt einen grösseren Durchmesser als der daran angrenzende zweite Abschnitt aufweist. Auch anders ausgestaltete Ausführungsformen der Füllkörper 5 sind denkbar und beliebig kombinierbar. The embodiment of the inventive bone replacement 1 shown in FIGS. 6 to 10 differs from the embodiment described in FIGS. 1 to 5 only in that the filling bodies 5 are T-shaped or mushroom-shaped. In this case, the filling bodies 5 may comprise two substantially circular-cylindrical sections, of which each a first section has a larger diameter than the second section adjoining thereto. Also differently configured embodiments of the packing 5 are conceivable and arbitrarily combinable.
Obwohl wie oben beschrieben verschiedene Ausführungsformen der vorliegenden Erfindung vorliegen, sind diese so zu verstehen, dass die verschiedenen Merkmale sowohl einzeln als auch in jeder beliebigen Kombination verwendet werden können. Diese Erfindung ist daher nicht einfach auf die oben erwähnten, besonders bevorzugten Ausführungsformen beschränkt. While various embodiments of the present invention are described above, it should be understood that the various features may be used both individually and in any combination. This invention is therefore not limited to the above-mentioned, particularly preferred embodiments.
Claims
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| CN112842636B (en) | 2015-12-16 | 2024-09-20 | 纽文思公司 | Porous spinal fusion implant |
| WO2017201371A1 (en) * | 2016-05-19 | 2017-11-23 | University Of Pittsburgh-Of The Commonwealth System Of Higher Education | Biomimetic plywood motifs for bone tissue engineering |
| US11638645B2 (en) | 2016-05-19 | 2023-05-02 | University of Pittsburgh—of the Commonwealth System of Higher Education | Biomimetic plywood motifs for bone tissue engineering |
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Also Published As
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| US20150297349A1 (en) | 2015-10-22 |
| US9907654B2 (en) | 2018-03-06 |
| WO2014089711A1 (en) | 2014-06-19 |
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