A research team led by the University of Sydney has presented a new 3D printing process that makes it possible to produce synthetic bone replacements with structures in the nanometer range. The aim of the development is to replicate the complex micro- and nanostructure of natural bone in order to produce implants that are not only stable, but also biocompatible and functionally integrated.
The method is based on a newly developed, printable bioceramic made of calcium phosphate, which is enriched with so-called prenucleation clusters. These clusters also play a role in natural bone formation, as they control mineralization and thus contribute to the strength of the tissue. The print resolution used is around 300 nanometers and therefore exceeds conventional techniques many times over.
“The technology brings us a step closer to transforming bone graft surgeries in the future,” said Professor Zreiqat, who this week was appointed as a 2025 Fellow of the American Institute for Medical and Biological Engineering for her work in musculoskeletal regeneration and successful technology commercialisation. “This reduces the risk of long-term complications and future surgeries and offers a more natural restoration of bone defects,” said Professor Zreiqat, whose team specialises in creating bio-ceramic materials that aim to recreate the structure and properties of real bone. “While the technology is still evolving, it represents a significant step in reconstructive surgery,” she said.
“Bone’s complex architecture is a masterpiece of nature,” said Professor Zreiqat, based at the School of Biomedical Engineering in the Faculty of Engineering. “Our bioceramic scaffolds aim to mimic the structure and properties of real bone. Just looking like bone is not enough – it needed to have similar strength and integrity. We were able to do it at the macro and micro level but achieving it at the nano level was the final piece of the puzzle,” said Professor Zreiqat.
The results, published in the journal Advanced Materials, were achieved at the Research and Prototype Foundry of the University of Sydney. The scientists involved emphasize that the next step is scalability and clinical applicability.
“This study demonstrates the potential to create bone-mimicking structures, paving the way for advanced bone grafts and implants,” said lead author Associate Professor Roohani, who completed the work at University of Sydney as part of Professor Zreiqat’s team and now leads the Advanced Biomaterials and Fabrication laboratory at UTS.
“This could revolutionise bioceramic implants, regenerative medicine and high-performance biomaterials,” he said.“Our bioceramic scaffolds aim to mimic the structure and properties of real bone. Just looking like bone is not enough – it needed to have similar strength and integrity”, said Professor Hala Zreiqat AM, Payne-Scott Professor of Biomedical Engineering. “Next, we’re advancing this technology by enhancing the scalability of our printed structures, accelerating their path to clinical application,” she said.
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