CN112500151B - 生物活性陶瓷支架与柔性可调的三维生坯及其制备方法 - Google Patents
生物活性陶瓷支架与柔性可调的三维生坯及其制备方法 Download PDFInfo
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Abstract
本发明公开了生物活性陶瓷支架与柔性可调的三维生坯及其制备方法。该方法包括:将流变助剂和阴离子多糖溶于水溶液中,与生物活性陶瓷粉末混合,形成生坯。利用挤出型三维(3D)打印机将上述生坯按照设定的形状挤出。然后,使用盐溶液进行交联,获得可塑的柔性生坯,按照需求二次成型后,进行相应的固化处理,得到具有复杂结构的生物活性陶瓷支架。该生物活性陶瓷支架的形状和孔隙结构可设计,使其符合促进细胞生长的要求,具有良好的机械性能和生物学性能。与现有技术相比,本发明可二次成型的柔性生坯适用于多种生物活性陶瓷,而且方法简单易行,可推广应用。
Description
技术领域
本发明属于3D打印及生物医用材料领域,具体涉及一种具有复杂结构的生物活性陶瓷支架与柔性可调的三维生坯及其制备方法。
背景技术
生物活性陶瓷支架因其具良好的生物相容性、生物可降解性以及骨诱导性而被广泛用于骨组织工程,其主要包括生物活性玻璃、磷酸钙骨水泥和羟基磷灰石等。由于形状可设、孔隙结构可调,3D打印成为了制备多孔生物活性陶瓷支架的主要方法,尤其是直接书写打印。
为了促进骨再生,最近的一些研究使用改进的喷嘴形成具有微通道的3D打印的生物活性陶瓷支架,例如空心管结构和莲藕状结构。但是,更复杂的结构(如皮质骨中相互连接的微通道结构(哈弗氏管))不可能直接通过现有的直接书写打印来制造。同时,具有一定曲率和孔隙结构的下颌骨、眶底和颅骨模型,很难直接通过直接书写打印获得。
生物活性陶瓷表现出强的离子和/或共价键,导致高硬度和低延展性机械性能,从而限制了其加工自由度。因此,在满足可打印的前提下,使生坯获得柔软性进行二次成型,制造相互连接的微通道结构或更复杂形状具有重要研究意义。目前,张等采用光固化墨水与陶瓷粉末进行混合打印,获得可二次变形的柔性生坯(Zhang D,Peng E,Borayek R,etal.Controllable Ceramic Green-Body Configuration for Complex CeramicArchitectures with Fine Features[J].Advanced Functional Materials,2019,29(12):1807082.)。但是,光固化墨水存在着陶瓷粉末含量低的问题,导致最后所得的支架力学性能差。相比之下,本发明可在较高的陶瓷粉末含量下,获得可二次变形的柔性生坯,进而获得力学性能较好的陶瓷支架。同时,目前对柔性生坯的应用主要在工艺陶瓷制品上,而针对生物活性陶瓷支架,特别是在生物医用材料上罕见报道。
发明内容
为了克服现有技术存在的不足,本发明的目的是提供一种具有复杂结构的生物活性陶瓷支架与柔性可调的三维生坯及其制备方法。
本发明目的是提供一种具有复杂结构的生物活性陶瓷支架及其可控生坯的制备方法,适用于3D打印。
本发明的目的至少通过如下技术方案之一实现。
本发明将生物活性陶瓷粉末和流变助剂/阴离子多糖水溶液混合获得生坯,获得按照设定的形状打印三维支架后使用盐溶液进行交联,然后二次成型后固化,得到具有复杂结构的生物活性陶瓷支架。
本发明结合阴离子多糖可离子交联的特性以及流变助剂的粘弹性,制备可控可打印的生坯。然后,结合3D打印技术以及二次成型的处理制备具有复杂结构的生物活性陶瓷支架,该支架的形状以及孔隙结构可调,形状保真度高,且具有良好的机械性能及生物学性能。制备方法简单易行,成本低廉。
本发明提供的柔性可调的三维生坯的制备方法,包括如下步骤:
(1)可打印生坯的制备:将生物活性陶瓷粉末与流变助剂/阴离子多糖水溶液混合,搅拌均匀,得到可打印生坯;
(2)柔性三维生坯的制备:将步骤(1)所述可打印生坯转移至挤出型三维打印机中,选用普通针头或者同轴针头,按照需求进行3D打印处理,得到3D打印制品,将所述3D打印制品浸泡在盐溶液中进行交联处理,可获得所述柔性可调的三维生坯。
本发明提供的柔性可调的三维生坯是通过使用不同的3D打印针头和打印模型的方式来有效调控支架本身的孔道结构、可加工度以及对应陶瓷支架的力学性能,所述的三维生坯可通过调节阴离子多糖水溶液的浓度、盐溶液的浓度及处理时间,获得不同弹性模量。
进一步地,步骤(1)所述生物活性陶瓷粉末包括磷酸钙骨水泥(即磷酸氢钙、磷酸三钙或磷酸四钙中的一种或一种以上按任意比例的组合物)、生物活性玻璃(由SiO2,Na2O,CaO和P2O5等基本成分组成的硅酸盐玻璃)、羟基磷灰石、镁黄长石及β-磷酸三钙等中的一种。
进一步地,步骤(1)所述流变助剂/阴离子多糖水溶液为流变助剂、阴离子多糖及水混合均匀得到的溶液;所述流变助剂为锂皂石、Pluronic F-127、卡波姆、纳米纤维素中的一种;所述阴离子多糖为海藻酸钠、羧甲基壳聚糖、羧甲基纤维素、卡拉胶水溶液中的一种以上;在步骤(1)所述流变助剂/阴离子多糖水溶液中,流变助剂的质量百分比浓度为1%-20%,阴离子多糖的质量百分比浓度为2%-10%。
进一步地,步骤(1)所述生物活性陶瓷粉末与流变助剂/阴离子多糖水溶液的质量比为1:0.4-0.8。
进一步地,步骤(2)所述盐溶液为氯化钙溶液及氯化钾溶液中的一种及以上;所述盐溶液的质量百分比浓度为1-10%;交联处理的时间为1min-30min。
进一步地,当步骤(1)所述阴离子多糖选用了海藻酸钠、羧甲基壳聚糖或羧甲基纤维素,步骤(2)所述盐溶液选用氯化钙溶液;当步骤(1)所述阴离子多糖选用了卡拉胶,步骤(2)所述盐溶液选用氯化钾溶液。
本发明提供一种由上述的制备方法制得的柔性可调的三维生坯,弹性模量为50-500kPa。
本发明提供的使用柔性可调的三维生坯制备具有复杂结构的生物活性陶瓷支架的方法,包括如下步骤:
将所述柔性可调的三维生坯进行二次变形处理,得到二次处理的生胚,然后固化处理,得到所述具有复杂结构的生物活性陶瓷支架。
进一步地,所述二次变形处理为卷曲、折叠、扭曲、修剪、压缩、扎孔和模具成型中的一种以上;当打印所得柔性可调的三维生坯的厚度、宽和长中任意两者比例在1:1.5-1:200内,所述二次变形处理包括卷曲及模具成型中的一种以上;当打印所得柔性可调的三维生坯的厚度、宽和长中任意两者比例在1:10-1:200内,所述二次变形处理包括折叠,当打印所得柔性可调的三维生坯的厚度、宽和长中任意两者比例在1:1-1:200内,所述二次变形处理中的扭曲;修剪、压缩和扎孔等处理不受柔性可调的三维生坯形状限制。
进一步地,所述固化处理包括恒温恒湿箱孵育处理和烧结处理中的一种以上;所述恒温恒湿箱孵育处理包括:将所述二次处理的生胚转移至温度为35-45℃,湿度为100%的恒温恒湿箱孵育7-14d;所述烧结处理包括:先将二次处理的生胚常温干燥24-48h,然后在350℃-450℃保持0.5-1h,然后升温至900℃-1350℃保持1h-5h;当所述柔性三维生坯为磷酸钙骨水泥打印完成后得到的,则固化处理采用恒温恒湿箱孵育处理;当所述柔性三维生坯为生物活性玻璃或羟基磷灰石打印完成后得到的,则固化处理采用烧结处理。
本发明提供一种由上述的制备方法制得的具有复杂结构的生物活性陶瓷支架。
与现有技术相比,本发明具有如下优点和有益效果:
(1)本发明解决了生物活性陶瓷加工自由度低的问题;本发明制备的生物活性陶瓷生坯具有良好的柔韧性,可使生坯在打印后二次变形或者修剪,方法简便,成本低;目前生物活性陶瓷打印的空心管结构需要使用抛光机才能暴露,而本发明只需要使用普通刀片切;
(2)与目前柔性生坯的制备方法对比,该方法所获得的具有复杂结构的生物活性陶瓷支架粉末含量高;
(3)本发明制备的具有复杂结构的生物活性陶瓷支架可兼备薄和一定曲率的结构,或者相互连接的微通道结构等复杂结构,组织贴合程度高以及氧气/养分的传输能力快,修复效果比普通结构的好。
附图说明
图1为实施例1磷酸钙骨水泥3d打印后二次处理的电镜图;
图2为实施例5中的镁黄长石柔性生坯(柔性可调的三维生坯)的压缩压缩循环的应力-应变关系图。
具体实施方式
以下结合附图和实例对本发明的具体实施作进一步说明,但本发明的实施和保护不限于此。需指出的是,以下若有未特别详细说明之过程,均是本领域技术人员可参照现有技术实现或理解的。所用试剂或仪器未注明生产厂商者,视为可以通过市售购买得到的常规产品。
实施例1
取1.2g纳米纤维素/海藻酸钠水溶液(纳米纤维素质量分数为1%,海藻酸钠质量分数为10%)与2g的α-磷酸三钙(磷酸钙骨水泥)粉末混合均匀,得到可打印生坯。
将得到的可打印生坯转移至挤出型3D打印机中,选用同轴针头(外针头尺寸为18G,内针头尺寸为23G)进行3D打印,打印完成后浸没至5wt%氯化钙溶液交联5min,得到柔性可调的三维生坯。该柔性可调的三维生坯内部具有空心管通道,其弹性模量为200kpa。
用刀片对上述柔性可调的三维生坯进行裁剪,将内部空心管通道暴露出来。采用自制的微针阵列(针的密度可调)对该结构进行处理,获得相互连接的微通道结构,然后在温度为35℃,湿度为100%的恒温恒湿箱孵育7d,得到具有相互连接的微通道结构的磷酸钙骨水泥支架(结构如附图1所示)。
实施例2
取1.5g海藻酸钠水溶液(海藻酸钠质量分数为10%)与2gα-磷酸三钙(磷酸钙骨水泥)粉末混合均匀,得到可打印生坯。将得到的可打印生坯转移至挤出型3D打印机中,选用同轴针头(外针头尺寸为18G,内针头尺寸为23G)进行3D打印,打印完成后浸没至7wt%氯化钙溶液交联3min,得到柔性可调的三维生坯。该柔性可调的三维生坯内部具有空心管通道,其弹性模量为50kpa,厚度与长度的比例在为1:5。
对上述柔性可调的三维生坯进行弯曲定型,使其具有一定曲率的支架。然后将该支架置于温度为45℃,湿度为100%的恒温恒湿箱孵育14d,得到具有一定曲率的空心管通道的磷酸钙骨水泥支架。
实施例3
取0.8g锂皂石/羧甲基纤维素水溶液(锂皂石质量分数为3%,羧甲基纤维素质量分数为2%)与2g生物活性玻璃45S5S粉末混合均匀,得到可打印生坯。
将得到的可打印生坯转移至挤出型3D打印机中,选用18G针头进行3D打印,打印完成后浸没至10wt%氯化钙溶液交联1min,得到柔性可调的三维生坯。该柔性可调的三维生坯无空心通道,其弹性模量为500kpa,厚度与长度的比例在为1:10。
对上述柔性可调的三维生坯进行折叠和模具定型,使其具有一定曲率的薄的支架,然后常温干燥24h后置于马弗炉中进行烧结,先在350℃保持1h,然后升温至1350℃保持5h,得到具有一定曲率的薄的生物活性玻璃支架。
实施例4
取1.1g卡波姆/羧甲基壳聚糖水溶液(卡波姆质量分数为2%,羧甲基壳聚糖质量分数为6%)与2g羟基磷灰石粉末混合均匀,得到可打印生坯。
将得到的可打印生坯转移至挤出型3D打印机中,选用21G针头进行3D打印,打印完成后浸没至1wt%氯化钙溶液交联30min,得到柔性可调的三维生坯。该柔性可调的三维生坯通道,其弹性模量为300kpa,厚度与宽度的比例在为1:200。
对上述柔性可调的三维生坯进行折叠并卷曲,使其具有层状同心圆结构(类似山楂卷)。然后常温干燥48h后置于马弗炉中进行烧结,先在450℃保持0.5h,然后升温至900℃保持3h,得到具有层状同心圆结构的羟基磷灰石支架。
实施例5
取1.4g Pluronic F-127/卡拉胶水溶液(Pluronic F-127质量分数为20%,卡拉胶质量分数为4%)与2g镁黄长石粉末混合均匀,得到可打印生坯。
将得到的可打印生坯转移至挤出型3D打印机中,选用同轴针头(外针头尺寸为19G,内针头尺寸为25G)进行3D打印,打印完成后浸没至3wt%氯化钾溶液交联15min,得到柔性可调的三维生坯。该柔性可调的三维生坯内部具有空心管通道,其弹性模量为180kpa。
对上述柔性可调的三维生坯进行裁剪、压缩并固定,使其空心管通道变扁(横截面从圆形变成椭圆形),然后常温干燥36h后置于马弗炉中进行烧结,先在400℃保持1h,然后升温至1200℃保持1h,得到具有椭圆状通道结构的镁黄长石支架。
实施例6
取1.6g Pluronic F-127/卡拉胶/海藻酸钠水溶液(Pluronic F-127质量分数为15%,卡拉胶质量分数为2%,海藻酸钠质量分数为4%)与2gβ-磷酸三钙粉末混合均匀,得到可打印生坯。
将得到的可打印生坯转移至挤出型3D打印机中,选用22G针头进行3D打印,打印完成后浸没至盐溶液(氯化钾的质量分数为3wt%,氯化钙的质量分数为3wt%)交联10min,得到柔性可调的三维生坯。该柔性可调的三维生坯细长但无空心通道,其弹性模量为450kpa,厚度与长度的比例在为1:1。
对上述柔性可调的三维生坯进行扭曲并固定,使其具有麻绳的扭纹结构。然后常温干燥42h后置于马弗炉中进行烧结,先在380℃保持0.8h,然后升温至1100℃保持2h,得到具有扭纹结构的β-磷酸三钙棒。
实验一、对比有和没有离子交联处理的生物活性陶瓷加工自由度
测定方法:使用同样比例的配方(此处的配方为实施例2制备的可打印生坯的配方)进行生物活性玻璃45S5S的3D打印,打印完后采取3种处理,观察所得现象:(1)直接裁切和模具定型后固化;(2)先离子交联后裁切和模具定型,再固化;(3)无处理直接固化后裁切和模具定型。结果如表1所示。
表1
序号 | 现象 |
(1) | 空心通道结构塌陷,印后无法转移至模具中 |
(2) | 获得空心通道结构,并与模具的设计形状相贴合 |
(3) | 无法完整裁切,支架崩裂;硬度太大,无法贴合模具形状。 |
图1为实施例1磷酸钙骨水泥3d打印后二次处理的电镜图,可见在结合3d打印及二次处理后,获得了相互连接的微通道结构。
图2为实施例5镁黄长石柔性生坯(柔性可调的三维生坯)压缩循环的应力-应变关系图,可见在循环压缩5次后,该生坯仍具有足够的回弹性恢复,故随后需要固定处理才能获得具有椭圆状通道结构的镁黄长石支架。其他实施例制备的柔性可调的三维生坯同样能在压缩后实现回弹性恢复,可参照图2所示。
以上实施例仅为本发明较优的实施方式,仅用于解释本发明,而非限制本发明,本领域技术人员在未脱离本发明精神实质下所作的改变、替换、修饰等均应属于本发明的保护范围。
Claims (10)
1.一种柔性可调的三维生坯的制备方法,其特征在于,包括如下步骤:
(1)将生物活性陶瓷粉末与流变助剂/阴离子多糖水溶液混合,搅拌均匀,得到可打印生坯;所述流变助剂/阴离子多糖水溶液为流变助剂、阴离子多糖及水混合均匀得到的溶液;所述流变助剂为锂皂石、Pluronic F-127、卡波姆、纳米纤维素中的一种;所述阴离子多糖为海藻酸钠、羧甲基壳聚糖、羧甲基纤维素、卡拉胶水溶液中的一种以上;在步骤(1)所述流变助剂/阴离子多糖水溶液中,流变助剂的质量百分比浓度为1%-20%,阴离子多糖的质量百分比浓度为2%-10%;所述生物活性陶瓷粉末与流变助剂/阴离子多糖水溶液的质量比为1:0.4-0.8;
(2)将步骤(1)所述可打印生坯转移至挤出型三维打印机中,按照需求进行3D打印处理,得到3D打印制品,将所述3D打印制品浸泡在盐溶液中进行交联处理,所述盐溶液为氯化钙溶液及氯化钾溶液中的一种及以上;所述盐溶液的质量百分比浓度为1-10%;交联处理的时间为1min-30min,可获得所述柔性可调的三维生坯。
2.根据权利要求1所述的柔性可调的三维生坯的制备方法,其特征在于,步骤(1)所述生物活性陶瓷粉末包括磷酸钙骨水泥、生物活性玻璃、羟基磷灰石、镁黄长石及β-磷酸三钙中的一种。
3.根据权利要求1所述的柔性可调的三维生坯的制备方法,其特征在于,当步骤(1)所述阴离子多糖选用了海藻酸钠、羧甲基壳聚糖或羧甲基纤维素,步骤(2)所述盐溶液选用氯化钙溶液;当步骤(1)所述阴离子多糖选用了卡拉胶,步骤(2)所述盐溶液选用氯化钾溶液。
4.一种由权利要求1-3任一项所述的制备方法制得的柔性可调的三维生坯,其特征在于,弹性模量为50-500kPa。
5.一种使用权利要求4所述柔性可调的三维生坯制备具有复杂结构的生物活性陶瓷支架的方法,其特征在于,包括如下步骤:
将所述柔性可调的三维生坯进行二次变形处理,得到二次处理的生胚,然后固化处理,得到所述具有复杂结构的生物活性陶瓷支架。
6.根据权利要求5所述的方法,其特征在于,所述二次变形处理为卷曲、折叠、扭曲、修剪、压缩、扎孔和模具成型中的一种以上;所述固化处理包括恒温恒湿箱孵育处理和烧结处理中的一种以上;所述恒温恒湿箱孵育处理包括:将所述二次处理的生胚转移至温度为35-45℃,湿度为100%的恒温恒湿箱孵育7-14d;所述烧结处理包括:先将二次处理的生胚常温干燥24-48h,然后在350℃-450℃保持0.5-1h,然后升温至900℃-1350℃保持1h-5h;当所述柔性三维生坯为磷酸钙骨水泥打印完成后得到的,则固化处理采用恒温恒湿箱孵育处理;当所述柔性三维生坯为生物活性玻璃或羟基磷灰石打印完成后得到的,则固化处理采用烧结处理。
7.根据权利要求5所述的方法,其特征在于,当打印所得柔性可调的三维生坯的厚度、宽和长中任意两者比例在1:1.5-1:200内,所述二次变形处理包括卷曲及模具成型中的一种以上。
8.根据权利要求5所述的方法,其特征在于,当打印所得柔性可调的三维生坯的厚度、宽和长中任意两者比例在1:10-1:200内,所述二次变形处理包括折叠。
9.根据权利要求5所述的方法,其特征在于,当打印所得柔性可调的三维生坯的厚度、宽和长中任意两者比例在1:1-1:200内,所述二次变形处理中的扭曲;修剪、压缩和扎孔处理不受柔性可调的三维生坯形状限制。
10.一种由权利要求5-9任一项所述的制备方法制得的具有复杂结构的生物活性陶瓷支架。
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