An interdisciplinary research team at the University of Waterloo is working on a 3D printable material that behaves like human bone and can be individually adapted to the anatomical conditions of individual patients. The aim is to make surgical interventions for bone damage more precise, safer and more efficient in the long term.
At the heart of the development is a nano-reinforced composite material consisting of a fat-like triglyceride and nanoscale hydroxyapatite. The latter is a mineral component of natural bone substance and performs several functions in the developed material: It provides the necessary mechanical strength and at the same time provides a biocompatible surface that facilitates the ingrowth of bone cells. As studies from 2024 show, these properties enable gradual integration and subsequent replacement of the implant with the body’s own tissue.
“I learned that the methods being used, though successful, were extremely complicated and required a lot of skill,” Dr. Thomas Willett, from the Department of Systems Design Engineering, said. “I thought we could do something with engineering, using 3D printing to produce a bone graft. 3D printing would also allow us to add engineered features that can hold the graft in place,” Willett said. “This would remove the need for the metal screws and plates that surgeons would normally use.
“We could have a material that you can fully customize to a patient, and that will have a big impact on the success of bone grafts and surgical outcomes”, said Elizabeth Diederichs (PhD in progress).
A customizable material that can be modelled using CT data and precisely manufactured using 3D printing would significantly improve the fit and biological integration. In addition, mechanical anchoring structures could be integrated directly into the print, eliminating the need for screws and plates.
“The hydroxyapatite particles play a few roles,” Willett explained. “They provide mechanical reinforcement, making the material stiffer and stronger. They also create a favourable surface for the material to combine with bone cells.”
“We can take CT scans and use computer-aided design to develop a model for the piece of bone that needs to be printed,” Willett said. “We could use this process for any bone that has lost a large piece or has complex geometry.” Printed bone grafts could also have applications for pets, reducing the need for amputations that impact quality of life.
The researchers are currently working on optimizing the material in terms of printability, mechanical resilience and degradability.
“I think it’s very exciting,” Diederichs said. “We could have a material that you can fully customize to a patient, and that will have a big impact on the success of bone grafts and surgical outcomes.”
In addition to human applications, the researchers also see potential in veterinary care, for example to prevent amputations in pets.
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