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Purpose The purpose of this study is to understand how printing parameters and subsequent annealing impacts porosity and crystallinity of 3D printed polylactic acid (PLA) and how these structural characteristics impact the printed material’s tensile strength in various build directions. Design/methodology/approach Two experimental studies were used, and samples with a flat vs upright print orientation were compared. The first experiment investigates a scan of printing parameters and annealing times and temperatures above the cold crystallization temperature ( T cc ) for PLA. The second experiment investigates annealing above and below T cc at multiple points over 12 h. Findings Annealing above T cc does not significantly impact the porosity but it does increase crystallinity. The increase in crystallinity does not contribute to an increase in strength, suggesting that co-crystallization across the weld does not occur. Atomic force microscopy (AFM) images show that weld interfaces between printed fibers are still visible after annealing above T cc , confirming the lack of co-crystallization. Annealing below T cc does not significantly impact porosity or crystallinity. However, there is an increase in tensile strength. AFM images show that annealing below T cc reduces thermal stresses that form at the interfaces during printing and slightly “heals” the as-printed interface resulting in an increase in tensile strength. Originality/value While annealing has been explored in the literature, it is unclear how it affects porosity, crystallinity and thermal stresses in fused filament fabrication PLA and how those factors contribute to mechanical properties. This study explains how co-crystallization across weld interfaces is necessary for crystallinity to increase strength and uses AFM as a technique to observe morphology at the weld. 

Bioresorbable bone adhesives are attractive materials for applications where bone repair, regeneration, or reconstruction is involved. They can potentially augment or replace metal fixation while allowing to avoid follow‐up procedures upon bone healing. Combining such bone adhesives with other clinically relevant materials could significantly improve the mechanical and biological properties of the resulting composite due to the strong adhesive interactions between the adhesive and the material. Herein, an efficient strategy is presented to create biomedically relevant biphasic scaffolds through filling 3D printed gyroid polymer or metal structures with a bioresorbable mineral‐organic bone adhesive. Due to the high interfacial adhesion of the bone adhesive and both polymers and metals, the biphasic scaffolds are efficiently stabilized by the bone adhesive, leading to a significant increase in the compressive strength and modulus. The 3D printed composite scaffolds infused with the bone adhesive possess improved mechanical properties and bioactivity while providing adhesion to bone facilitated by the bone adhesive regions and could potentially considerably improve clinical outcomes in orthopedic applications.

 

Despite advances in biomaterials research, there is no ideal device for replacing weight‐bearing soft tissues like menisci or intervertebral discs due to poor integration with tissues and mechanical property mismatch. Designing an implant with a soft and porous tissue‐contacting structure using a material conducive to cell attachment and growth could potentially address these limitations. Polycarbonate urethane (PCU) is a soft and tough biocompatible material that can be 3D printed into porous structures with controlled pore sizes. Porous biomaterials of appropriate chemistries can support cell proliferation and tissue ingrowth, but their optimal design parameters remain unclear. To investigate this, porous PCU structures were 3D‐printed in a crosshatch pattern with a range of in‐plane pore sizes (0 to 800 μm) forming fully interconnected porous networks. Printed porous structures had ultimate tensile strengths ranging from 1.9 to 11.6 MPa, strains to failure ranging from 300 to 486%, Young's moduli ranging from 0.85 to 12.42 MPa, and porosity ranging from 13 to 71%. These porous networks can be loaded with hydrogels, such as collagen gels, to provide additional biological support for cells. Bare PCU structures and collagen‐hydrogel‐filled porous PCU support robust NIH/3T3 fibroblast cell line proliferation over 14 days for all pore sizes. Results highlight PCU's potential in the development of tissue‐integrating medical implants.

 

Critical‐sized defects remain a significant challenge in orthopaedics. 3D printed scaffolds are a promising treatment but are still limited due to inconsistent osseous integration. The goal of the study is to understand how changing the surface roughness of 3D printed titanium either by surface treatment or artificially printing rough topography impacts the mechanical and biological properties of 3D printed titanium. Titanium tensile samples and discs were printed via laser powder bed fusion. Roughness was manipulated by post‐processing printed samples or by directly printing rough features. Experimental groups in order of increasing surface roughness were Polished, Blasted, As Built, Sprouts, and Rough Sprouts. Tensile behavior of samples showed reduced strength with increasing surface roughness. MC3T3 pre‐osteoblasts were seeded on discs and analyzed for cellular proliferation, differentiation, and matrix deposition at 0, 2, and 4 weeks. Printing roughness diminished mechanical properties such as tensile strength and ductility without clear benefit to cell growth. Roughness features were printed on mesoscale, unlike samples in literature in which roughness on microscale demonstrated an increase in cell activity. The data suggest that printing artificial roughness on titanium scaffold is not an effective strategy to promote osseous integration.

 

Inspired by the avoidance of toxic chemical crosslinkers and harsh reaction conditions, this work describes a poly(vinyl alcohol)‐based (PVA) double‐network (DN) hydrogel aimed at maintaining biocompatibility through the combined use of bio‐friendly additives and freezing–thawing cyclic processing for the application of synthetic soft‐polymer implants. This DN hydrogel is studied using techniques that characterize both its chemical and mechanical behavior. A variety of bio‐friendly additives are screened for their effectiveness at improving the toughness of the PVA hydrogel system in monotonic tension. Starch is selected as the best additive for further tensile testing as it brings about a near 30% increase in ultimate tensile strength and maintains ease of processing. This PVA–starch DN sample is then studied for its tensile fatigue properties through cyclic, strain‐controlled testing to develop a fatigue life curve. Though an increase in monotonic tensile strength is observed, the PVA–starch DN hydrogel does not bring about an improvement in the fatigue behavior as compared to the control. Although synthetic hydrogel reinforcement is widely researched, this work presents the first fatigue analysis of its kind and it is intended to serve as a guide for future fatigue studies of reinforced hydrogels.

 

Bioresorbable bone adhesives have potential to revolutionize the clinical treatment of the human skeletal system, ranging from the fixation and osteointegration of permanent implants to the direct healing and fusion of bones without permanent fixation hardware. Despite an unmet need, there are currently no bone adhesives in clinical use that provide a strong enough bond to wet bone while possessing good osteointegration and bioresorbability. Inspired by the sandcastle worm that creates a protective tubular shell around its body using a proteinaceous adhesive, a novel bone adhesive is introduced, based on tetracalcium phosphate and phosphoserine, that cures in minutes in an aqueous environment and provides high bone‐to‐bone adhesive strength. The new material is measured to be 10 times more adhesive than bioresorbable calcium phosphate cement and 7.5 times more adhesive than non‐resorbable poly(methyl methacrylate) bone cement, both of which are standard of care in the clinic today. The bone adhesive also demonstrates chemical adhesion to titanium approximately twice that of its adhesion to bone, unlocking the potential for adherence to metallic implants during surrounding bony incorporation. Finally, the bone adhesive is shown to demonstrate osteointegration and bioresorbability over a 52‐week period in a critically sized distal femur defect in rabbits.