Control of the size, shape and composition of highly uniform, non-agglomerated, sub-micrometer β-tricalcium phosphate and dicalcium phosphate platelets

Calcium phosphates (CaPs) are widely used as bone graft substitutes but are inherently brittle, hence restricting their use to mechanically protected environments. Combining them with a tough polymer matrix could potentially lead to a composite with load-bearing properties. However, the highest mechanical properties can only be achieved if the CaP particles possess very precise features: they should be uniform in size and shape, non-agglomerated, elongated and thin. The aim of the present study therefore was to assess a novel method to produce such particles. This involved the precipitation of CaP particles in ethylene glycol at moderate temperatures (90-170 °C) and the variation of different reaction parameters (temperature, concentration, pH, etc) to study their influence on particle composition, size, shape and dispersion was studied. As a result, two main CaP phases were obtained as well-dispersed and highly uniform platelets in the form of: (i) β-tricalcium phosphate (β-TCP) hexagonal prisms and (ii) monetite (DCP) flat parallelepipeds. The size dispersion was the narrowest for β-TCP (standard deviation/mean < 5%) whereas the aspect ratio was the highest for DCP (up to 25). In both cases, the thickness of the platelets was below 300 nm which should be ideal for the synthesis of strong CaP-based composites.