Papers by Author: A.W. Miles

Abstract: Several novel methods for the production of calcium phosphate based functional gradient materials have been explored. The processes involved the use of polyurethane foams with a different number of pores per inch which were joined together in a variety of ways to form unique templates prior to vacuum impregnation with a ceramic slip. Before processing, rectangular blocks of foam were joined by stitching or trapezoidal blocks were compressed into rectangular shapes to produce a gradient of porosity along the length of the template. Four-point bend testing of the sintered samples which combined two porous structures showed them to have comparable mechanical properties to homogeneous ceramics based on foam templates with uniform pore sizes, with no evidence of weakness at the interface. The method was further developed to make a cylindrical sample with two diverse porous structures which more closely mimic the natural bone morphology. The two very different areas, which represented cortical and cancellous bone, had good structural integrity at the interface.

Abstract: Ceramic slips with powder loadings in the range of 80-140 wt% were used to investigate the effect of slip loading on the physical and mechanical properties of open pore HA/TCP bioceramics. The results indicated that increasing the slip loading had an effect on the properties of the samples. The average apparent density, the work of fracture and compressive strength all increased with slip loading. In contrast, the effect of increasing slip loading on the four-point bending strength was not significant.

Abstract: Calcium phosphate (CaP) ceramics possessing an interconnecting porosity network in the appropriate size range for vascularisation offer the possibility of providing a structural matrix for replacement of diseased or damaged bone. Such bioceramics must possess sufficient mechanical strength to avoid failure whilst offering a bioactive surface for bone regeneration. The objective of the current study was to produce a hydroxyapatite/tricalcium phosphate (HA/TCP) bioceramic that imitated the orientated trabecular structure found in cancellous bone. The structure-property relationship of these bioceramics was then analysed. It was hypothesised that the mechanical properties would be linked to the shape of the pore structure due to the orientation of the open porous scaffolds (OPS) produced. OPS bioceramics possessed an interconnected macroporosity network of 40-70% by volume with bending strengths of 0.30MPa ± 0.01MPa and apparent densities of 0.35g/cm3 ± 0.05g/cm3. Typically, pore sizes in the range of 150-300µm were produced. The fabrication of CaP OPS resulted in a wide range of macroporosity in the correct size range for osseointegration to occur. Elongating the pore structure did not affect the total porosity of the bioceramics. Strengths were low due to microcrack formation on sintering and not due to the shape of the pores present in the scaffold as initially hypothesised.

Abstract: The aim of this study was to fabricate porous Hydroxyapatite/Tricalcium phosphate (HA/TCP) bioceramics with an adequate degree of interconnected porosity combined with optimal mechanical properties. Porous HA/TCP bioceramics with interconnected porosity and the controlled pore sizes necessary to simulate natural bone tissue morphology were fabricated by a novel technique of vacuum impregnation of reticulated polymeric foams with ceramic slip. By varying the characteristics of the slips and using foams of different pores per inch (ppi), samples of porous HA/TCP, blocks and granules, with a wide range of pore sizes were successfully manufactured. Functionally gradient materials (FGM) with porosity gradients were also made and no weakness was found at the interface. The pore size of the HA/TCP bioceramics was in the range of 197 – 254 µm (for 20 ppi foam), 143 – 182 µm (for 30 ppi foam) and 105 – 127 µm (for 45 ppi foam). The compressive strengths and the apparent densities of the HA/TCP samples were in the range of 30 –170 MPa and 2.34 – 2.76 g/cm3 respectively. These results indicate that it is possible to manufacture open pore HA/TCP bioceramics with compressive strengths comparable to human bone which could be of clinical interest.