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<p>Digital Light Processing (DLP) 3D printing enables fabrication of dense, patient-specific ceramic components with high dimensional accuracy, but design rules for bioactive zirconia–calcium-silicate (Zr–CS) composites remain poorly defined. Here, high-solid-loading DLP was used to manufacture dense Zr–CS discs containing 0, 10, 30, and 50 wt% dicalcium silicate (Ca₂SiO₄), which were debound and sintered at 1300&#xa0;°C. Microstructural analysis showed progressive pore formation and grain boundary separation with increasing CS content. Compressive strength for CS-containing composites increased from 82.63 to 122.04&#xa0;MPa between 10 and 50 wt% CS (<i>p</i> &lt; 0.05), but remained lower than pure zirconia (170.19&#xa0;MPa). In contrast, Young’s modulus and Vickers hardness decreased monotonically with CS addition, reflecting the higher porosity and microstructural discontinuities. Indirect-contact assays with human mesenchymal stem cells (hMSCs) showed that 10 wt% CS maintained metabolic activity comparable to control, whereas 30–50 wt% CS significantly reduced metabolic activity after 4 days of eluate exposure (<i>p</i> &lt; 0.05). Direct-contact experiments corroborated this trend: cells attached and spread well on pure Zr and 10 wt% Zr–CS, but coverage and nuclear count were markedly reduced at ≥ 30 wt% CS. By combining quantitative porosity, mechanical properties, and dual-mode cytocompatibility on the same sintered parts, this work identifies a practical design window for dense Zr–CS composites: ≤10 wt% CS balances structural integrity with cytocompatibility, while higher CS fractions primarily serve as boundary compositions defining mechanical and biological limits. High-solid-loading DLP Zr–CS composites therefore offer a route to bone-relevant stiffness tuning and controlled bioactivity for next-generation dental implants.</p>

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3D digitally printed zirconia dicalcium silicate biomaterial for dental applications: mechanical and cytocompatibility testing

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年3月30日

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  • Ahmed Binobaid,
  • Dhanak Gupta,
  • Bahauddeen M. Alrfaei,
  • Josette Camilleri,
  • Hany Hassanin,
  • Khamis Essa

摘要

Digital Light Processing (DLP) 3D printing enables fabrication of dense, patient-specific ceramic components with high dimensional accuracy, but design rules for bioactive zirconia–calcium-silicate (Zr–CS) composites remain poorly defined. Here, high-solid-loading DLP was used to manufacture dense Zr–CS discs containing 0, 10, 30, and 50 wt% dicalcium silicate (Ca₂SiO₄), which were debound and sintered at 1300 °C. Microstructural analysis showed progressive pore formation and grain boundary separation with increasing CS content. Compressive strength for CS-containing composites increased from 82.63 to 122.04 MPa between 10 and 50 wt% CS (p < 0.05), but remained lower than pure zirconia (170.19 MPa). In contrast, Young’s modulus and Vickers hardness decreased monotonically with CS addition, reflecting the higher porosity and microstructural discontinuities. Indirect-contact assays with human mesenchymal stem cells (hMSCs) showed that 10 wt% CS maintained metabolic activity comparable to control, whereas 30–50 wt% CS significantly reduced metabolic activity after 4 days of eluate exposure (p < 0.05). Direct-contact experiments corroborated this trend: cells attached and spread well on pure Zr and 10 wt% Zr–CS, but coverage and nuclear count were markedly reduced at ≥ 30 wt% CS. By combining quantitative porosity, mechanical properties, and dual-mode cytocompatibility on the same sintered parts, this work identifies a practical design window for dense Zr–CS composites: ≤10 wt% CS balances structural integrity with cytocompatibility, while higher CS fractions primarily serve as boundary compositions defining mechanical and biological limits. High-solid-loading DLP Zr–CS composites therefore offer a route to bone-relevant stiffness tuning and controlled bioactivity for next-generation dental implants.