A novel manufacturing route for the fabrication of topologically-ordered open-cell porous iron scaffold

Pure iron is gaining significance in the field of bone tissue engineering owing to its excellent mechanical and biodegradable properties. However, its degradation rate is too slow which needs to be accelerated. The solution to this problem is the preparation of porous iron scaffolds. However, methods for preparing porous iron have received the least attention and till date, no manufacturing methodology for fabrication of topologically-ordered porous iron structures has been developed. Hence, the present work aims to develop a manufacturing methodology using 3D printing and pressureless microwave sintering for the fabrication of topologically-ordered open cell porous iron scaffold. Two different types of unit cell structures were fabricated, and investigation into the accuracy of fabricated iron scaffolds has been reported. The dimensional deviation varying from 5 to 15% was obtained with the porosity varying within the range of 80-86%. Also, XRD results revealed that no contamination of mould material as well as oxide formation was observed in the fabricated iron scaffolds. Compression tests were performed on the fabricated iron scaffolds. The maximum value of plateau stress, compressive modulus of elasticity and compressive strength were found to be 6.94 MPa, 316 MPa and 16.67 MPa respectively.