<p>Achieving ceramics that combine stiffness, strength, and toughness in complex geometries remains a major challenge, limiting their use in applications such as bone implants. Bio-inspired architectures – composed of stiff, strong building blocks connected by deformable interfaces – offer a promising solution. However, their implementation is constrained by limited control over the arrangement and composition of blocks, especially in constructs with complex shapes at centimeter- to meter-scale. We present a light-based printing method that deposits and assembles interlocking ceramic building blocks onto connecting micro-pins, inspired by nacre’s growth mechanism. A custom alumina resin was developed and printed using a tabletop LCD 3D printer, sintered, and subsequently infiltrated with polycaprolactone, a tough and biocompatible polymer that forms the deformable interfaces. The resulting nacre-like constructs, with 76-78 wt% (50-52 vol%) ceramic, showed flexural stiffness of 2.27 ± 0.44 GPa, strength of 41.4 ± 1.33 MPa, and energy absorption of at least 6.35 ± 0.97 MJ.m<sup>-3</sup>. These values match the energy absorption of cortical bone, exceed the rule-of-mixtures value by fivefold, and surpass that of monolithic ceramic by over 4000 times. Finally, a 4 cm-long nacre-like construct replicating the geometry of the human tibia was fabricated and tested in flexion, demonstrating scalability and potential for biomedical applications.</p>

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Growing synthetic nacre via simultaneous printing and assembly of interlocking ceramic building blocks

  • Zizhen Ding,
  • Reza Shakibanezhad,
  • Travis Klein,
  • Mohammad Mirkhalaf

摘要

Achieving ceramics that combine stiffness, strength, and toughness in complex geometries remains a major challenge, limiting their use in applications such as bone implants. Bio-inspired architectures – composed of stiff, strong building blocks connected by deformable interfaces – offer a promising solution. However, their implementation is constrained by limited control over the arrangement and composition of blocks, especially in constructs with complex shapes at centimeter- to meter-scale. We present a light-based printing method that deposits and assembles interlocking ceramic building blocks onto connecting micro-pins, inspired by nacre’s growth mechanism. A custom alumina resin was developed and printed using a tabletop LCD 3D printer, sintered, and subsequently infiltrated with polycaprolactone, a tough and biocompatible polymer that forms the deformable interfaces. The resulting nacre-like constructs, with 76-78 wt% (50-52 vol%) ceramic, showed flexural stiffness of 2.27 ± 0.44 GPa, strength of 41.4 ± 1.33 MPa, and energy absorption of at least 6.35 ± 0.97 MJ.m-3. These values match the energy absorption of cortical bone, exceed the rule-of-mixtures value by fivefold, and surpass that of monolithic ceramic by over 4000 times. Finally, a 4 cm-long nacre-like construct replicating the geometry of the human tibia was fabricated and tested in flexion, demonstrating scalability and potential for biomedical applications.