“Steel–Concrete” Inspired Biofunctional Layered Hybrid Cage for Spine Fusion and Segmental Bone Reconstruction

In this paper we report a “steel–concrete” inspired layered hybrid spine cage combining a titanium mesh and a bioceramic scaffold, which were welded together through a bioglass bonding layer using a novel multistep manufacturing methodology including three-dimensional slip deposition, gel casting, freeze-drying, and cosintering. The interfacial welding strength achieved 27 ± 0.7 MPa, indicating an excellent structural integrity of the hybrid cage construct. The biocramic scaffold layer consisting of wollastonite and hydroxyapatite had an interconnected, highly porous structure with a pore size of 100–500 μm and a porosity of >85%, well fufilling the structural requirements of bone regeneration. Simulated body fluid immersion assay showed that the hybrid cage exhibited excellent biodegradability to facilitate rapid bone-like apatite formation. In vitro studies demonstrated that the bioceramic scaffold on the hybrid cage supported attachment, spreading, growth, and migration of bone/vessel-forming cells and triggered osteogenic differentiation of human mesenchymal stem cells. In vivo studies further suggested that the bioceramic scaffold on the hybrid cage could actively promote fast generation of new bone tissues within 12 weeks of implantation in a rabbit femoral condyle model. This study has provided a new design and fabrication methodology of hybrid cages by integrating strong mechanical properties with excellent biological activities including osteoinductivity and bone regeneration ability, for spine fusion and segmental bone reconstruction.