Ahlhelm, MatthiasMatthiasAhlhelmLaterro, Sergio H.Sergio H.LaterroMayr, Hermann O.Hermann O.MayrStorch, ChristianeChristianeStorchFreytag, ChristianChristianFreytagWerner, DavidDavidWernerSchwarzer-Fischer, EricEricSchwarzer-FischerSeidenstücker, MichaelMichaelSeidenstücker2022-03-062022-03-062021https://publica.fraunhofer.de/handle/publica/27046210.3390/jcs51002812-s2.0-85118385197The authors report on the manufacturing of mechanically stable v-tricalcium phosphate (v-TCP) structural hybrid scaffolds via the combination of additive manufacturing (CerAM VPP) and Freeze Foaming for engineering a potential bone replacement. In the first step, load bearing support structures were designed via FE simulation and 3D printed by CerAM VPP. In the second step, structures were foamed-in with a porous and degradable calcium phosphate (CaP) ceramic that mimics porous spongiosa. For this purpose, Fraunhofer IKTS used a process known as Freeze Foaming, which allows the foaming of any powdery material and the foaming-in into near-net-shape structures. Using a joint heat treatment, both structural components fused to form a structural hybrid. This bone construct had a 25-fold increased compressive strength compared to the pure CaP Freeze Foam and excellent biocompatibility with human osteoblastic MG-63 cells when compared to a bone grafting Curasan material for benchmark.enFreeze Foamhybrid bonebiocompatibilitybone replacement610620666620journal article