Rapid prototyping of ceramic lattices for hard tissue scaffolds

Hard tissue engineering scaffolds were prepared by micro-extrusion freeforming using biphase calcium phosphate powders. This technique allows both the shape and a hierarchical pore structure within the shape to be designed on the computer and promptly downloaded onto a three-axis building platform. We report on the implementation of six types of design in which the systematic exploration of different void structures can be achieved using one sample configuration. In this way, void sizes from 50 μm to 500 μm are built into a lattice such that histological studies can deliver the maximum information from the minimum of testing. This technique also allows multi-scale hierarchies of void structure to be built into one component such that large voids intended for vascularisation can accompany smaller recesses which can host osteoblast development as well as conferring mechanical strength.