New Tissue Engineering Technology Used for Making Bone Implants

A method of producing synthetic bone is being developed using techniques normally used to manufacture catalytic converters for cars.

Researchers at the University of Warwick (United Kingdom) developed the new technique, which involves state-of-the-art extrusion of the implant material through a mould to produce a three-dimensional (3D) honeycomb texture with uniform pores throughout. The material can then be sculpted by the surgeon to precisely match the defect. After implantation, bone cells are transported into the implant where they begin to form new bone. The increased strength of the material means it could be used in spinal surgery or in revision hip and knee operations where currently non-degradable materials such as titanium or steel are usually used. The advantage of increased and interconnected porosity is that the implant can quickly be filled with blood vessels, resulting in a more rapid healing process. The new research was presented at Bioversity 2008, a UK national university technology-showcase event held during December 2008 in London (United Kingdom).

"We worked with a Japanese company which manufactures catalytic converters and used their facility to produce samples which we could then test in the laboratory," explained the new method's co-developer Kajal Mallick, Ph.D. "We found that we were able to use calcium phosphates - a family of bioceramics that are routinely used in bone implant operations, but by using this technique we were able to improve significantly both the strength and porosity of the implant."

"The synthetic bone we are developing is as strong as normal healthy bone yet porous enough to allow bone cells to inhabit it and generate new bone. Over a period of time, we expect the synthetic bone will resorb, leaving only natural bone," added James Meredith, M.Sc., who is working to complete an Engineering Doctorate in this research area. "I hope that if we can find an industrial partner to take this to market, we will enable treatment of conditions which up to this point have only been possible using metal replacement parts or low strength foam-like bone substitutes."

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