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The osteoinductivity of 3D printed calcium phosphate (CaP) ceramics has a large gap compared with those prepared by conventional foaming methods, and improving the osteoinductivity of 3D printing CaP ceramics is crucial for successful application in bone regeneration. Pore architecture plays a critical role in osteoinductivity. In this study, CaP ceramics with a hexagonal close-packed (HCP) spherical pore structure were successfully fabricated using DLP printing technology. Additionally, octahedral (Octahedral), diamond (Diamond), and helical (Gyroid) structures were constructed with similar porosity and macropore diameter. CaP ceramics with the HCP structure exhibited higher compression strength (8.39 ± 1.82 MPa) and lower permeability (6.41 × 10−11 m2) compared to the Octahedral, Diamond, and Gyroid structures. In vitro cellular responses indicated that the macropore architecture strongly influenced the local growth rate of osteoblast-formed cell tissue; cells grew uniformly and formed circular rings in the HCP group. Furthermore, the HCP group promoted the expression of osteogenic genes and proteins more effectively than the other three groups. The outstanding osteoinductivity of the HCP group was confirmed in canine intramuscular implantation studies, where the new bone area reached up to 8.02 ± 1.94 % after a 10-week implantation. Additionally, the HCP group showed effective bone regeneration in repairing femoral condyle defects. Therefore, our findings suggest that 3D printed CaP bioceramics with an HCP structure promote osteoinductivity and can be considered as candidates for personalized precise treatment of bone defects in clinical applications. 1. 3D printing BCP ceramics with high osteoinductivity were constructed through pore architecture optimization. 2. BCP ceramics with HCP structure exhibited relatively higher mechanical strength and lower permeability than those with Octahedral, Diamond and Gyroid structures. 3. BCP ceramics with HCP structure could promote the osteogenic differentiation of MC3T3-E1, and showed the superior in-vivo osteoinductivity and bone regeneration comparing with the other structures. [Display omitted] [ABSTRACT FROM AUTHOR]

Digital light processing (DLP)-based 3D printing technique holds promise in fabricating scaffolds with high precision. Here raw calcium phosphate (CaP) powders were modified by 5.5% monoalcohol ethoxylate phosphate (MAEP) to ensure high solid loading and low viscosity. The rheological tests found that photocurable slurries composed of 50 wt% modified CaP powders and 2 wt% toners were suitable for DLP printing. Based on geometric models designed by computer-aided design (CAD) system, three printed CaP ceramics with distinct macroporous structures were prepared, including simple cube, octet-truss and inverse face-centered cube (fcc), which presented the similar phase composition and microstructure, but the different macropore geometries. Inverse fcc group showed the highest porosity and compressive strength. The in vitro and in vivo biological evaluations were performed to compare the bioactivity of three printed CaP ceramics, and the traditional foamed ceramic was used as control. It suggested that all CaP ceramics exhibited good biocompatibility, as evidence by an even bone-like apatite layer formation on the surface, and the good cell proliferation and spreading. A mouse intramuscular implantation model found that all of CaP ceramics could induce ectopic bone formation, and foam group had the strongest osteoinduction, followed by inverse fcc, while cube and octet-truss had the weakest one. It indicated that macropore geometry was of great importance to affect the osteoinductivity of scaffolds, and spherical, concave macropores facilitated osteogenesis. These findings provide a strategy to design and fabricate high-performance orthopedic grafts with proper pore geometry and desired biological performance via DLP-based 3D printing technique. [ABSTRACT FROM AUTHOR]

[Display omitted] • A complete process study of DLP-based 3D printing CaP ceramics was investigated, including the initial powder and dispersant selection, slurry preparation, printing parameters optimization, post-treatment and so on. • The post-curing treatment could eliminate the interlayer cracks on the surface and improve the structural uniformity of the green body. • BCP-3D exhibited better osteogenic activity and bone regenerative repair ability than the commercial one of BCP-Foam, reaching the repair effect of the autograft. Acquiring high-performance calcium phosphate (CaP) ceramics via 3D printing is critical for their applications in bone regenerative repair. In current study, a complete process study of 3D printed CaP ceramics based on digital light processing (DLP) technology was performed to get the ideal implant for the regenerative repair of calvarial defects. The smaller particle size of initial powder would be more favorable to getting slurry with high solid content and low viscosity. CaP green body with high precision and high curing rate could be fabricated at the exposure energy density and exposure time of 6.20 mJ cm−2 and 2 s, respectively. Moreover, the post-curing treatment could eliminate the interlayer cracks and increase the curing rate from 69.78% to 93.91% of green body. After that, the mechanical strength of CaP ceramics increased by 46.34%. In-vitro cellular experiments showed that 3D printed CaP ceramics had good biocompatibility, and could promote the osteoblastic differentiation of BMSCs. In-vivo rat cranial defect implantation revealed 3D printed CaP ceramics exhibited better osteogenic ability than the commercial ones (BAM®), reaching the close level with the autografts. Overall, this study could provide a closed-loop solution for 3D printed CaP ceramics with high-precision and low-defect to induce bone regeneration. [ABSTRACT FROM AUTHOR]