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<p>Porous hydroxyapatite (HAp) scaffolds have excellent osteoinductive and osteoconductive properties, but with inferior mechanical strength. On the other hand, silicon nitride (SN) is a bioinert ceramic with high mechanical properties. Harnessing these twin characteristics, ceramic fused filament fabrication (CF<sup>3</sup>) of HAp-SN is postulated to develop bone scaffolds with improved mechanical and biological properties. Pure HAp and HAp-SN-based 3D printable filaments were developed with high solid loading of 75 wt%. L9 Taguchi design of experiments (DOE) yielded multiple groups of the printing parameters (print speed, extrusion multiplier, and input %infill). The influences of different DOE on layer thickness, bead width, surface roughness, and part density were experimentally quantified. After optimizing the printing parameters using pure HAp, the HAp-SN biocomposites were CF<sup>3</sup> printed using the optimized parameters for biocompatibility and mechanical properties evaluation. Proliferation, differentiation, and mineralization of murine pre-osteoblasts were quantified on the CF<sup>3</sup> printed-sintered HAp and HAp-SN scaffolds. Extrusion multiplier of 0.8 and print speed of 10–15&#xa0;mm/s manifested the optimized printing results. Surface roughness in the parallel direction (~ 11&#xa0;µm) was less than the perpendicular surface roughness (~ 15&#xa0;µm). Based on the results, multi-variable regression analysis of the input printing parameters could predict the layer thickness, bead width, surface roughness, and printed %infill impressively (<i>R</i><sup>2</sup> = 91–99%), with moderate density prediction (<i>R</i><sup>2</sup> = 70%). Enhanced wettability, compressive strength (35 ± 6&#xa0;MPa), and cytocompatibility were observed in HAp-10% SN, while benchmarked against pure HAp scaffolds. The major influencer to achieve expected layer thickness, bead width, surface roughness, and printed %infill was found to be the “extrusion multiplier,” followed by the “print speed.” Enhanced osteogenic differentiation and mineralization along with the mechanical property improvements endorsed the potential of CF<sup>3</sup> processed HAp-10%SN biocomposite in bone tissue engineering applications.</p>

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Optimization of Ceramic Fused Filament Fabrication (CF3) for Enhanced Mechanical and Biological Properties of Hydroxyapatite-Silicon Nitride Biocomposites

  • 期刊论文

  • 发表日期：

    2025年3月20日

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  • Kavish Sudan,
  • Srimanta Barui,
  • Paramjot Singh,
  • Jyotirmaya Behera,
  • Kunal H. Kate,
  • Vamsi Krishna Balla,
  • Neetu Tyagi

摘要

Porous hydroxyapatite (HAp) scaffolds have excellent osteoinductive and osteoconductive properties, but with inferior mechanical strength. On the other hand, silicon nitride (SN) is a bioinert ceramic with high mechanical properties. Harnessing these twin characteristics, ceramic fused filament fabrication (CF3) of HAp-SN is postulated to develop bone scaffolds with improved mechanical and biological properties. Pure HAp and HAp-SN-based 3D printable filaments were developed with high solid loading of 75 wt%. L9 Taguchi design of experiments (DOE) yielded multiple groups of the printing parameters (print speed, extrusion multiplier, and input %infill). The influences of different DOE on layer thickness, bead width, surface roughness, and part density were experimentally quantified. After optimizing the printing parameters using pure HAp, the HAp-SN biocomposites were CF3 printed using the optimized parameters for biocompatibility and mechanical properties evaluation. Proliferation, differentiation, and mineralization of murine pre-osteoblasts were quantified on the CF3 printed-sintered HAp and HAp-SN scaffolds. Extrusion multiplier of 0.8 and print speed of 10–15 mm/s manifested the optimized printing results. Surface roughness in the parallel direction (~ 11 µm) was less than the perpendicular surface roughness (~ 15 µm). Based on the results, multi-variable regression analysis of the input printing parameters could predict the layer thickness, bead width, surface roughness, and printed %infill impressively (R2 = 91–99%), with moderate density prediction (R2 = 70%). Enhanced wettability, compressive strength (35 ± 6 MPa), and cytocompatibility were observed in HAp-10% SN, while benchmarked against pure HAp scaffolds. The major influencer to achieve expected layer thickness, bead width, surface roughness, and printed %infill was found to be the “extrusion multiplier,” followed by the “print speed.” Enhanced osteogenic differentiation and mineralization along with the mechanical property improvements endorsed the potential of CF3 processed HAp-10%SN biocomposite in bone tissue engineering applications.