Bone tissue engineering is an emerging interdisciplinary field in science, combining expertise in medicine, material science and biomechanics. It aims at a patient specific reconstruction of large bone defects by applying a porous scaffold that acts as a (temporary) skeleton for biologically active substances. The requirements posed on the possible candidate for bone scaffold are numerous, ranging from material aspects to the porous architecture itself. Pore size distributions and interconnectivity should be sufficient for cell seeding and cell migration, vascularization and mass transport from and to the cells.

This study focus on 2 manufacturing routes which are applied on calcium phosphates and titanium (alloys). Gel casting is a direct foaming technique starting from a metallic or ceramic suspension. The biomimetic architecture consists in pore size distribution from 100 µm to 800 µm. The porous structure is characterized with electron microscopy, image analysis and Hg intrusion porosimetry. Bioresobable ceramic foams are manufactured with well controllable composition of (biphasic) calcium phosphates. Preliminary in vitro testing yield different dissolution rates for the varying compositions. When aiming at load bearing applications, titanium foams can be produced, with a tunable mechanical strength and high ductility values.

Rapid prototyping technologies include a large number of technologies, among which 3D fiber deposition (3DFD). Starting from a highly viscous paste, a computer controlled 3D movement of the paste reservoir allows the continuous deposition of thin fibers of a ceramic or metallic paste. The porous architecture is governed by the fiber thickness and fiber spacings and is characterized by narrow distributions. Due to the high mechanical properties and the influence on cell behaviour, the introduction of microporosity in the fibers is achievable.

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