Washington State University

Rutgers, the State University of New Jersey

Amit Bandyopadhyay

Susmita Bose

Ahmad Safari

Stephen C Danforth

Rajesh K Panda

Victor F Janas

Mukesh Agarwala

Weichang Xue

John Ballato

Remco Van Weeren

Thomas Gualtieri

Thomas McNulty

Yanning Zhang

Jonathan C Christensen

Particular aspects provide novel devices for bone tissue engineering, comprising a metal or metal-based composite member/material comprising an interior macroporous structure in which porosity may vary from 0-90% (v), the member comprising a surface region having a surface pore size, porosity, and composition designed to encourage cell growth and adhesion thereon, to provide a device suitable for bone tissue engineering in a recipient subject. In certain aspects, the device further comprises a gradient of pore size, porosity, and material composition extending from the surface region throughout the interior of the device, wherein the gradient transition is continuous, discontinuous or seamless and the growth of cells extending from the surface region inward is promoted.

Bone replacement materials

Techniques of additive deposition for producing articles of manufacture are disclosed herein. In one embodiment, an article of manufacture can include a substrate having a surface and composed of a metal or metal alloy and multiple layers of composite materials deposited on the surface of the substrate. The composite materials is composed of the metal or metal alloy and a ceramic material. The individual composite materials at each of the multiple layers has a composition with a corresponding ratio between the metal or metal alloy material and the ceramic material. The ratios between the metal or metal alloy material and the ceramic material change along at least one dimension of the article of manufacture.

Additive manufacturing of composite materials with composition gradient

A metal matrix has a biocompatible solid lubricant in at least a portion of its surface and the solid lubricant functions to protect the interior of the metal matrix and minimize the friction coefficient and related wear induced damage at the articulating surface of the metal device. The lubricated biocompatible metal device is made of materials compatible for in vivo and ex vivo applications in order to minimize wear induced degradation as well as metal ion release. The lubricated biocompatible metal device is suited for use as medical implants.

Wear resistant low friction coefficient surfaces for joint and bone replacement materials and devices

Particular aspects of the present disclosure provide bio-resorbable and biocompatible compositions for bioengineering, restoring, or regenerating tissue or bone. In one embodiment, a biocompatible composition includes a three-dimensional porous or non-porous scaffold material comprising a calcium phosphate-based ceramic having at least one dopant therein selected from metal ion dopants or metal oxide dopants. The composition is sufficiently biocompatible to provide for a cell or tissue scaffold, and resorbable at a controlled resorption rate for controlled strength loss under body, body fluid or simulated body fluid conditions.

Resorbable ceramics with controlled strength loss rates

The present disclosure is directed to modified metal materials for implantation and/or bone replacement, and to methods for modifying surface properties of metal substrates for enhancing cellular adhesion (tissue integration) and providing antimicrobial properties. Some embodiments comprise surface coatings for metal implants, such as titanium-based materials, using (1) electrochemical processing and/or oxidation methods, and/or (2) laser processing, in order to enhance bone cell-materials interactions and achieve improved antimicrobial properties. One embodiment comprises the modification of a metal surface by growth of in situ nanotubes via anodization, followed by electrodeposition of silver on the nanotubes. Other embodiments include the use of LENS&#x2122; processing to coat a metal surface with calcium-based bioceramic composition layers. These surface treatment methods can be applied as a post-processing operation to metallic implants such as hip, knee and spinal devices as well as screws, pins and plates.

Modified metal materials, surface modifications to improve cell interactions and antimicrobial properties, and methods for modifying metal surface properties

Mesoporous calcium silicate compositions for controlled release of bioactive agents and methods for producing such compositions are disclosed herein. In one embodiment, mesoporous calcium silicate is synthesized by acid modification of wollastonite particles using hydrochloric acid. A hydrated silica gel layer having abundant Si&#x2014;OH functional groups can be formed on the surface of wollastonite after acid modification. Bruhauer-Emmett-Teller (BET) surface area increased significantly due to acid modification and, in one arrangement, reached over 350 m/g. Acid modified mesoporous calcium silicate compositions show a higher ability to adsorb protein compared to unmodified particles and demonstrate controlled release kinetics of these proteins.

Mesoporous calcium silicate compositions and methods for synthesis of mesoporous calcium silicate for controlled release of bioactive agents

Various embodiments of surface-modified devices, components, and associated methods of manufacturing are described herein. In one embodiment, an implantable device suitable for being implanted in a patient includes an implantable material having a utile shape and a surface and a modification material deposited on at least a portion of the surface of the implantable material. The modification material has a release rate in an implantation environment in the patient. The modification material at the release rate is effective as bactericidal without being cytotoxic to the patient.

Materials with modified surfaces and methods of manufacturing

Provided are devices for bone tissue engineering, comprising a metal or metal-based composite member comprising an interior macroporous structure with porosity varying from 0-90% (v), the member comprising a surface region having a surface pore size, porosity, and composition designed to encourage cell growth and adhesion thereon, to provide a device engineered for a particular recipient subject. Engineered devices may further comprises a gradient of pore size, porosity, and material composition extending from the surface region throughout the interior of the device, wherein the gradient transition is continuous, discontinuous or seamless to promote cell in-growth. Additional aspects provide methods for bone tissue engineering, comprising use of a metal or metal-based composite member comprising an interior porous structure, wherein the pore size, porosity and material composition is selected to provide a device having an optimal density and/or elastic modulus and/or compression strength for a specific recipient. Fabrication methods are provided.

Particular aspects provide bioresorbable and biocompatible compositions for bioengineering, restoring or regenerating tissue or bone, comprising a three-dimensional porous or non-porous scaffold material comprising a calcium phosphate-based ceramic having at least one dopant therein selected from metal ion or ion dopants and metal oxide dopants, wherein the composition is sufficiently biocompatible to provide for a cell or tissue scaffold, and resorbable at a controlled resorption rate for controlled strength loss, depending on dopant composition, under body, body fluid or simulated body fluid conditions. Preferably, the at least one dopant is selected from the group consisting of Zn, Mg, Si, Na, K, Sr, Cu, Fe/Fe, Ag, Ti, CO, F, MgO, ZnO, NaF, KF, FeO/FeO, SrO, CuO, SiO, TiO, AgO and CaCO, present in an amount between 0 and about 10 w %, from about 0.5 to about 5 w %, or from about 1 to about 3 w %, and methods of using same.

A reverse engineering technique allows the creation of 3-D CAD files from a solid model. A solid model of a part to be reverse engineered is created from polymers having an index of refraction matching that of an immersion liquid. Over the immersion liquid is a masking liquid that is substantially opaque. The generally clear polymeric model of the part is moved through the immersion/masking layer interface while images of the cross section of the model are acquired at the interface layer. The images are then used to create digital solid models from a physical model or to compare an existing physical model with its digital model.

Reverse engineering of polymeric solid models by refractive index matching

This invention relates to a new class of piezoelectric composites with a radial design. More particularly, the radial design of these new ceramic/polymer composites show a higher sensitivity in the radial direction than conventional tube structured devices. Devices made utilizing this novel design will therefore show significantly enhanced performance in many applications.

Radial ceramic piezoelectric composites

A process for making ceramic composites includes the steps of: a) forming a polymer composition into a three-dimensional mold; b) filling said three-dimensional mold with one or more ceramic containing compositions; c) heating said filled mold to dry and sinter the ceramic; d) removing at least a portion of said three-dimensional mold thereby forming voids; and e) filling the voids with a second composition which has a piezoelectric coefficient which is substantially different from the piezoelectric coefficient of said ceramic structure. Steps a through e yield a controlled, non-random piezoelectric ceramic composite having 2-3, 3-2 or 3--3 connectivity with respect to the sintered ceramic and the second composition throughout the composite.

Methods for producing novel ceramic composites

Solid freeform fabrication techniques are used in direct methods to form photonic bandgap structures, and in indirect methods to form molds for photonic bandgap structures. In the direct methods, solid particulate materials are mixed with a binder and, through a computer-controlled process, are built layer by layer to form the structure. In the indirect methods, unfilled polymeric materials are built layer by layer to form a negative mold for the photonic bandgap structure. The cavities within the mold may then be filled with a slurry incorporating solid particulate materials. Subsequent processing may include mold removal, binder removal, densification and secondary infiltration steps to form a photonic bandgap structure having the desired properties.

Growing community of inventors

Pullman, WA, United States of America

Amit Bandyopadhyay