WO2013165333A1

WO2013165333A1 - Bone putty

Info

Publication number: WO2013165333A1
Application number: PCT/US2012/032066
Authority: WO
Inventors: David Franklin Farrar; Nicola Jayne MACAULEY; John Rose
Original assignee: Smith & Nephew, Inc.
Priority date: 2011-04-04
Filing date: 2012-04-04
Publication date: 2013-11-07
Also published as: MX343651B; AU2012376506A1; CN104023757A; MX2013011607A; JP2014528734A; BR112013025495A2; CN104023757B; RU2013148890A; AU2012376506B2; US20140128990A1; EP2696907A1; ZA201307317B

Abstract

The present invention relates to a macroporous material for filling bone voids. In particular, we describe an implant material comprising bioresorbabte polymer granules and a biocompatible water-miscib!e solvent, wherein the solvent at least partially dissolves and/or softens the polymer granules to form a mouldabie mass that can be used to fill a bone defect but hardens when water is added and/or the implant material is placed in an aqueous environment, and wherein the implant material has macroporosity suitable for bone in-growth.

Description

Bone Potty

The present Invention relates to bone void fillers, in particular, the. present invention relates to a macroporous material for filling bone voids,

The present invention concerns macroporous materials for bone repair and bone void filling. Ideally, the material should be mouitiabie/formable so that it can fill and conform to irregular shaped and sized bone defects. However, once implanted if ideally should set hard so that the implant material maintains its shape and, under some circumstances, be able to bear loads. The materia! should not break up and needs to foe tough. Furthermore, the materia! should allow rapid bone in-growth and, ultimately, be degradabie and fully replaced by bone, in order to facilitate bone repair the material may incorporate a drug or bioactive molecule which is released fo stimulate bone healing and repair.

A numbe of bone void filter materials are known, but very fe meet all the idea! re uirements.

Poiy(methyl methacrytate) bone cements are widely used to fixate joint replacements but these materials are non*porous and non-degradabie so they are not replaced by bone. In addition, when the cement cures, heat is generated and the temperature of the material can rise to 90°C or above. This can damage any drug material or bioactive agent which have been added to the cement, particularly if the bioactive agent consist of proteins such as bone morphogeneic protein (BMP) etc.

Calcium phosphate ceramics, such as hydroxyapafiie and tncalcium

phosphate, are widely used for bone void filling. These filters are available in a number of forms. For example, the use of dense and porous granules is known. These can be used to fill irregular shaped defects and allow bone growth into and between the granules. However, they cannot maintain a specific shape or form, and fend to migrate if not fully contained. Porous blocks in pre-formed shapes are also known. However, whilst these kinds of fillers maintain their shape, they cannot be used to fill irregular sized/shaped defects- in addition, It is not easy to incorporate a drug or bioactive materia! into these ceramics as high temperatures are required in their manufacture. Drugs o bioactive agents can be adsorbed or coated onto the surface of these ceramics but they tend to be released very quickly;

Calcium phosphate cements have also been used as bone fillers. These kinds of fillers have the advantage of being mouSdable, and even injectable, and once in place they set hard. However, whilst they may contain micropores, these tend not to allow significant levels of bone ingrowth. Some calcium phosphate cements have macropores but these generally compromise the mechanical strength of the material. In addition, calcium phosphate ceramics (blocks, cements etc) generally tend to form brittle materials.

There have been attempts to produce bone void ^'filters which harden i -situ; these combin ceramic granules with a polymer. US 201070041770 discloses a composite material formed by mixing a polymer phase with a solvent, adding a bioresorbable ceramic phase, and thereafter allowing the solvent to diffuse out of the polymer in the presence of water, to cause solidification of the polymer phase. The composite formed does not have initial porosity for rapid bone in- growth, though pores may form iater by degradation of one of the phases.

US 2005/0251266 discloses a moutdahie composite comprising ceramic granules coated with a biocompatible polymer and a plasticizer such that the polymer is Initially deformable and then hardens upon removal of the plasticizer by placing in water. However, coating the granules is difficult and the specialist processes which need to be employed leads to an increase in cost In addition, since all the granules ar coated with polymer there is a delay in the

osteoinductive effect of the bioeeramie granules until at least some of the polymer degrades.

The present invention seeks to address at least som of these problems by providing a macroporous material for filling bone voids, which preferably includes one or more of the following characteristics: is mouSdahSe/formab!e; sets to a hard and tough material; is able to bear loads; allows for rapid bone irvgrowth; and is biodegradable and substantially replaced by bone without substantially compromising the structural integrity of the sit© of application.

In its broadest sense the present invention provides a bone void filler comprising a bioresorbable granulated polymer and a biocompatible water- miscible solvent.

According to the present invention there is provided an implant materia! for bone void filling comprising bioresorbable polymer granules and a

biocompatible water-miscible solvent, wherein the solvent at least partially dissolves and/or softens the polymer granules to form a mouldabte mass that can be used to fsl! a bone defect, but which hardens whe the implant materia! is exposed to wafer, arid wherein the implant materia! has macroporosity suitable for bone in-growth.

Suitably, the implant material contains pores of between about SO and 3000 microns; preferably 100 and 2000 microns; more preferably 120 and 1500 microns, which pores provide a macroporosity level suitable for bone in-growth, Suitably, the implant material has an open porosity greater than 15%.

Preferably, the implant materia! has an open porosity of between about 15%- 70%; more preferably about 20%-55%; most preferably about 25%-45%.

Upon addition of the biocompatible water-miscible solvent to the bioresorbable polymer granules th granules soften and or partially or full dissolve causing them to become "sticky" and form a mouldable or f!owab!e mass that can be delivered to the bone defect and which conforms to the shape of the defect, in the presence of water or an aqueous environment, such as being placed in the body, the solvent is removed and the implant material hardens into a mass with interconnected macroporosity,

Suitably, the bioresorbable po!ymer granules include particles, flakes or powder. Suitably, the implant material further includes a bioceramic material, Suitably, the bioceramlc materia! is formed as a mixture with the bioresorbable polymer. Preferably, the bioceramlc material comprises granules, flakes or powder. In embodiments comprising a bioceramlc powder, the powder may be dispersed within the bioresorbable polymer or bioresorbable polymer granules.

Preferably, the bioceramlc material is porous. Suitably, the bioceramlc material contains pores of between about 10 and 1000 microns; preferabl 15 and 500 microns; more preferably 20 and 300 microns,

Suitably, the bioresorbable polymer granules include a core formed of a

different material. Suitably, the core Is formed from a second bioresorbable poiymer which is different to the polymer of the bioresorbable polymer granules. Alternatively, the core is formed from a bioceramic material. Preferably, the bioceramic material is a bioceramic granule or powder. Optionally, the core includes an inner core and an outer core, wherein the inner core is formed from a bioceramic material and the outer core is formed from a second

bioresorbable polymer. The core may also be formed from a bioresorbable polymer having a bioceramic powder dispersed therein, In such embodiments, the powder may be uniformly or non*ur»formiy dispersed.

Optionally, the implant material includes a bioactive or therapeutic agent.

Suitably, the core Includes a bioactive or therapeutic agent. Preferably, the outer core includes a bioactive or therapeutic agent.

Preferably, the bioactive or therapeutic agent includes at ieast one of: a growth factor such as any bone morphogenic protein (BMP), platelet derived growt factor (PDGF), growth hormone, transforming growth factor-beta (TGF-beta), insulin-like growth factor; a bisphosphonate such as alendronate, zotedronate; an antibiotic such as gentamicin, vancomycin, tobramycin; an anti-cancer drug such as paclitaxel, mercatopurine; an anti-inflammatory agent such as salicylic acid, indomethacine; an analgesic such as salicylic acid. The bioactive or therapeutic agent may also be incorporated into the implant material by; coating onto the bioceramie granules; incorporating within the bioceramie granules; coating onto the polymer granules; incorporating within the polymer granules; incorporating within the biocompatible solvent; adding at the time of mixing the components or any combination of these methods to give a desired dispersion and release profile.

Preferably, the second bioresorbable polymer is less soluble in the

biocompatible solvent than the first bioresorbable polymer. In this way, when the solvent is added, the surface of the bioresorbable polymer granules becomes softened and/o partially dissolves but the outer core layer, preferably containing a bioactive or therapeutic agent, remains largely intact. The bioactive or therapeutic agent will be released from the outer core Iayer as the first bioresorbable polymer is absorbed.

Optionally, the same or a different bioactive or therapeutic agent can be incorporated into the first bioresorbable polymer. Suitably, where the bioactive or therapeutic agents are the same theyhave different release rates according to the different releas characteristics and/or degradation rates of the first and second bioresorbable polymers.

Preferably, the bioceramie granules include at least one of: calcium phosphate, including hydroxyapatite, any substituted hydroxyapatrte (e.g. silicon, carbonate, magnesium, strontium, fluoride), tncalcium phosphate, Diphasic calcium phosphate, fefracaicium phosphate., octacalcium phosphate, dicaicium phosphate dihydrate (brushite), dicaicium phosphate^' (monettte), calcium pyrophosphate, calcium pyrophosphate dihydrate, heptacalcium phosphate, calcium phosphate monohydrate; calcium sulphate; any bioactive glass (e,g. Bioglass) or glass ceramic (e.g. apatite-woSlastonite); or any combination of these. The granules may be dense or porous.

Preferably, the first bioresorbabl polymer includes at least one of: any polymer from the poly-a!pha-hydroxyacid group, including poly(iactic acid), poiytglycoilc acid), poly-L-Saetide, poly-DL-lactide, poiyilactide-co-g!ycolide), poly(lactide-co- caprotactone), polyibfcctide-co-DMactld©), polyeaprolactone; any

bioresorbable polyanhydride, pofyamide, polyorthoester, polydioxanone, polycarbonate, polyamlnoacid. poiy{amino-esfer)_s poly(amido-carbonate}^' ₍ polyphosphazene, poiyether, polyurethane, polyeyanoacry!ate, or any combination of these.

Preferably, the second bioresorbable polymer includes at teas! one of: a polymer from the poSy-aSpha-hydroxyaeid group, including poly(lactic acid), poly{giycoSic acid), poiy-L-lactide, poiy-DL-lactide, poly(!actide-co-glycoifde}, poiy{iaotide-oo-caprolactone)_; poly(L actlde-co*DL-lact!de), polycaprolactone; any bioresorbable polyanhydride, poiyamide, poiyorthoester, polydioxanone, polycarbonate, polyaminoacid, poly(amino-ester)_f poiy amido-car onate), polyphosphazene, polyetlw, poSyurethane. potycyanoacrylate; a

polysaccharide optionally including alginate, cn!tosan, carboxymethyS cellulose, hydroxypropylmet yl cellulose, dextran, hyaluronic acid, or any combination of these.

Preferably, the biocompatible, water rniscible solvent includes at teas! one of; -meihyi-pyroiSidone, dimethyl sulphoxkfe, acetone, polyethylene glycol), tetrahy rofu an, isopropanol, or caproSactone.

Optionally the implant material includes a water soluble porogen that is not soluble in the biocompatible solvent Preferably, the water solubie porogen includes at (east one of: a soluble inorganic salt such as sodium chloride; any soluble organic -compound such as sucrose; or a w ter soluble polymer such as polyethylene glycol), polyvinyl alcohol}, polysaccharide such as

carboxymethySceliu!ose,

Compared with poly{ methyl methacrylate) bone cements, aspects of the present invention are macroporous and fully bioresorbable,

Compared with bioceramsc blocks, aspects of the present invention have the advantage of being injectable and/or mouidab!e and capable of conforming to irregular shaped bone defects. Compared with bioceramic granules, -aspects of the present invention have- the advantage of hardening irt-situ to form a cohesive mass, thus preventing the possibility of granuies migrating. This couid be particularly advantageous when the implant is being used to deliver a drug or therapeutic agent, particularly one which stimulates bone formation, such as BMP, as it reduces the possibility of bone forming in unwanted areas ~ particularly important if the implant is being used in areas such as the spine where there may be nerves etc near to the bone implant.

Compared with the implant material of US 2010/0041770, aspects of the invention described here have the advantage of having immediate connected macroporosity suitable for rapid bone ingrowth, Compared with the implant material of US 2006/0261266, aspects of the present invention keep at least some of the bloactive/therapeutie molecule within an intact coating layer which is not removed from the granules when the biocompatible solvent is added. This allows for better control and sustained release of the molecule. Also, in embodiments having more than one layer of polymer coating with different release and/or degradation profiles, the overall release of drug can be tailored or the system used to deliver different compounds with different release profiles. In addition, aspects of the invention do not require pre-coating of the ceramic granules, and furthermore, the fact that a portion of the granules comprise a bioresorbable polymer allows for the creation of greater porosity as the polymer granules degrade allowing more room for bone in-growth over time. In addition, we here disclose th use of wafer fo modify the viscosity of the implant materia! prior to implantation in order to achieve the desired handling characteristics. The viscosity of the implant material prior to hardening can be adjusted by the addition of wafer after the addition and mixing of the solvent. If an

injactable/fiowab!e material is desired then no water is added but by adding water prior to implantation a more pufly-like/mouldable consistency can be achieved, The above and other aspects of the invention wili now be described with reference to the following drawings in which; is a schematic illustration of a first embodiment, according to the present invention, of an implant material for bone void filling; is a schematic illustration of a second embodiment, according to the present invention, of an implant material for bone void filling; is a schemati illustration of a third embodiment, according to the present invention, of an implant material for bono void filling; is a schematic illustration of a fourth embodiment, according to the present invention, of an implant material for bone void filling; is a schematic illustration of a fifth embodiment, according to the present Invention, of an implant material for bone void filling; Figure 6 is a schematic illustration of a sixth embodiment, according to the present invention, of an implant material for bone void filling;

Figure 7 is a schematic illustration of a seventh embodiment, according to the present invention, of an Implant material for bone void filling; Figure .8 is a schematic illustration of an eighth embodiment, according to the present invention, of an implant materia! for bone void filling; Figure 9 is a schematic illustration of a ninth embodiment, according to the present invention, of an implant material for bone void filling; and

Figure 10 is a close-up schematic view of the embodiment of Figure 9.

Referring to Figure 1 ₍ there is shown schematically an impiant material precursor for bone void fitting comprising poiymer granules 10 and a

biocompatible solvent 1 1. As the solvent 11 is mixed with the poiymer granules the solvent softens and tackifies the outer surface of the polyme granules, giving them a 'sticky' character. In this state, the granules adhere together to form a cohesive, mou!dable implant material. The implant materia! can then be used to fill bone voids and defects (not shown). The biocompatible solvent is preferably water-miscible. In the presence of water or an aqueous

environment, such as being placed in the body, the solvent is removed and the implant material hardens into a mass with interconnected macroporosity.

Consequently, the macroporous materia! allows for tissue ingrowth, particularly bone tissue ingrowth. The polymer granules are formed from sor a le materials such as

poiy(lac ic acid), poly(glycolic acid), poiy-L-lacfide, poly-DL-lactide, poiy{!actsde- co-giycolide), poiy actide-CQ-eaprolactcne), poiyiUaetide-CQ-DL-lactide), po!ycaprolactooe; any bioresorbable polyanhydride, polyamide, po!yorthoester, po!ydioxanone, polycarbonate, poiyaminoacid, poSyiamino-ester}, poly{amido- carbonate), polyphosphazene, polyetrter, pofyurethane, polycyanoacry!ate, or any combination of these, and as the polymer degrades and is absorbed by the bod new bone forms and advances to replace substantially all of the polymer material. The biocompatible water mtscible solvent may be selected from: N-roethyf- pyrollidone, dimethyl -suiphoxide, acetone, polyethylene glycol),

fetrahydrofuran, isopropanol, or capro!actone. As shown in Figures 2 and 4, a porogen 12 can be incorporated in the implant materia! leading to the formation of further macropores within the set composition. Typically, the porogen will be a soluble inorganic salt such as sodium chloride; a soluble organic compound such as sucrose; or a water soluble polymer such as polyfethySene glycol), poiy(viny! alcohol),

polysaccharide such as carbox methyicelluiose.

The implant material may also include a bioceramic materia! in the form of granules 13, as illustrated in Figure 3. The bioceramic material may be at least one of: calcium phosphate, including hydroxyapatite, a substituted

hydroxyapatite (e,g, silicon, carbonate, magnesium, strontium, fluoride), tricaleium phosphate, triphasic calcium phosphate, tetracalcium phosphate, ocfaca!cium phosphate, dicalcium phosphate dihydrate (brushite), dlcalcium phosphate (monetrte). calcium pyrophosphate, calcium pyrophosphate dihydrate, heptacaScium phosphate, calcium phosphate monohydrate; calcium sulphate; a bioactive glass or glass ceramic; or any combination of these.

According to this embodiment, the solvent softens and tackifies the outer surface of the polymer granules, making them sticky. The granules then adhere to each other and also the bioceramic granules, and as the solvent is removed, the polymer hardens arid incorporates the bioceramic granules in the set macroporous structure. The bioceramic granules add strength and rigidit to the implant material, and are osteoinductive to encourage bone imgrawth. Further, because only the outer surface of the polymer granuies is softened, the polymer does not spread to coat the surface of the bioceramic granules, and therefore much of the outer surface of the biocermaic granules remains exposed. Accordingly, there is substantially no delay to initiation of the osteoinductive effect. fn further alternative embodiments shown in Figures 5 and 6, the biocompatible solvent fully dissolves the polymer granules in the presence of the bioceramic granules and forms a coating 14 over each surface. This can be achieved in the presence or absence of a parogen. Alternatively, a similar result can be achieved by pre-mixing the solvent and polyme and then adding the

bioceramic granules, and optionally a porogen, to this mixture in order to form the implant material (Figures 7 and 8),

The implant material may also include a bioactive or therapeutic agent.

Examples of such include, but are not limited to a growth factor such as a bone morphogeny protein (BMP), platelet derived growth factor (PD6F), growth hormone, transforming growth factor-beta (TGF-beta), insulin-like growth factor; a bisphos^'pho ate such as alendronate, zoledronate; an antibiotic such as gentamicin, vancomycin, tobramfcin; an anti-cancer drug such as paclitaxel, mercatopyrine; an anti-inflammatory agent such as salicylic acid,

indomethaclne: or an analgesic such as salicylic acid, in further embodiments of the invention, shown in Figures 9 and 10, the bioresorbable polymer granules include a core formed of a different material, The core material may be a different bioresorbable polymer, having different properties to the first bioresorbable polymer granules, or may be a bioceramic material. In embodiments which incorporate a bioceramic core, the material will be a bioceramic granule or powder. In further embodiments, the core includes an Inner core and an outer core, where the inner core Is formed from a bioceramic material and the outer core is formed from a second bioresorbable polymer.

Referring to Figure 10, there is shown a polymer granule formed from a first bioresorbable polymer. The polymer granule includes a core having an inner core formed from a bioceramic material, and an outer core, formed from a second bioresorbable polymer. The first bioresorbable polymer will be at least partially soluble in the biocompatible solvent so that it provides adhesion between granules. If the first bioresorbable polymer Includes a bioactive or therapeulsc agent, it may provide a initial release of thai agent as the polymer starts to degrade and b absorbed.

The second bioresorbable polymer may be: a polymer comprising a poJy-alpha- hydroxyacid group, including poty(lactic acid), poly(giycoiic acid), poiy-L-lacftde, poly-DL-!actide, polyi!actide-co-giyco!ide}, poSyCiactlde-co-caproiacione}, poly L- iactide-co-DL-Saetide), poSycaproSactone; any bioresorbable polyanhydrtde, polyamide, polyorthoester, polydioxanone, polycarbonate, polyaminoacid, poly amino-esfer), poly(amido-carbonats), polyphosphate, polyeiher, polyur ethane, polycyanoaerytate; a polysaccharide comprising alginate, chitosam earboxymethyi cellulose, hydroxypropylmethyl cellulose, dextran, hyaluronic acid, or any combination of these. The second bioresorbable polymer is generally less solubl in the biocompatible solvent. Where bioactive or therapeutic agents are incorporated In the second bioresorbable polymer, this allows for a sustained release of said agent.

Examples Example 1

Materials: β-tricalcium phosphate granules {GenOs 1-2mrn_t supplied by Orthos Lid); pofy-DL-lactide-co-giycolide (PDLGA) 85:15 (Puresorb, supplied by

Purac); N-metriyl-pyrollidone {HUP) (supplied by Sigma-A!drich),

Prior to use the PDLGA raw granules were reduced in particle size by cryo- milling for a total of about 6 minutes to a final particle size <1 mm.

Method: 1 ml TCP granules was mixed with 1mi PDLGA 85:15 granules. O.Sml of NMP was added and the mixture was stirred and kneaded with a spatula until it formed a putty-like consistency. The mass could be moulded in the hands. It was placed in a cylindrical plastic mould (internal diameter - 11 ,8mm) and packed using finger pressure. The materia! was then pushed out of the mould and was seen to maintain its shape, it was placed in deion!zed water at room temperature. After approximately 5 minutes the sample was removed and had hardene sufficiently that if was no longer mou!dabie. it was observed thai the material had maintained porosity between: the fused granules.

The sample was stored overnight in deionized water at 37 . After 24 hours the cylindrical samples were ail cut to a height of i ,5cm and tested in compression using an Instron 5669 Universal Testing Machine at a rate of 5mm/min,

Compression testing gave a yield stress of 5.5MPa. There was no peak in the stress-strain curve indicating a tough material

Compression Testin of Exampie i

Example 2

Example 1 was repeated but this time 1m! of NMP- was added. In this case the polymer granules fully dissolved and a solid plug was formed with less visible porosity. The sample was stored in deionized water at 37*C and tested in compression as described in Example 1. Compression testing gave a yield stress of 4 Pa. There was no peak in the stress-strain curve indicating a tough material. Compression Testing of Exam le 2

0 30 40

Compressiv St ain

Example 3

1 mi of TCP was mixed with 0,25ml of PDLGA 85: 18. 1 ml of N P was then added and stirred to dissolve the polymsr. The mixture in this case was fiowable and less putty-like then the previous exampies. However, when 1 ml of water was added to the mass it immediately became more cohesive and putty- like, it was packed into the mould using finger pressure as before and then pushed out into deionized water. After about 5 minutes the sample was removed and the plug had hardened. It appeared more porous than examples 1 and 2. The sample was stored in deionized water at 3?*C and tested in compression as described in Example 1 , Compression testing gave a peak stress of 1 M Pa. Compression Testing of Example 3

0 5 10 15 20 25 30 35 40

Compressive Strain {¾}

Example 4

0.6ml of TCP was mixed with 0,5m! sucrose (granulated ···^■ supplied by Sigma- Aidrich, Product Code 84097) and 0.5ml POLGA 85; 15. 0.5m! HMP was added to the mixture and stirred and kneaded with a spatula to form a putty. Again the mixture was packed into the mould then pushed out into water. After about 5 minutes the samp!e was removed and examined and seen to have hardened. Pores were visible between the granules and a!so from the dissolution of the sucrose. The sample was stored in deionized water at 37°C and tested in compression as described in Exampl 1 . The sample gradually collapsed under cornpresston and no yield point or peak stress was visible on the stress- strain curve. ■Compression Testing of Example 4

0 10 20 30 40 50 60 70

Comp essi e Strait} ¾ }

Example 5

0.5ml TCP was mixed with 0,5 ml sucrose and 0.25 mi PDLGA 85:15. 1 ml of HMP was added. As for Example 3, a flowa !e system was formed, 0.5 mi water was added and this caused the mixture to form a putty-like consistency. Again if was packed into the rnouid and pushed out into water. After about 5 minutes the sample was examined and seen to have hardened. Pores were visible between the granules and also from the dissolution of the sucrose. The sample was stored in deionized water at 3?*C and tested in compression as described in Example 1 . The sample gradually collapsed under compression and no yield point or peak stress was visible on the stress-strain curve.

Comp essi n Testing of Example 6

0 10 SO 30 40 SO 80 70

Compressive Strain {¾

Example 6

I ffli TCP was mixed with 0.5m! powdered POLGA 60:50 (supplied by AJdrich (The PL6A was not cryo-milled as it was already in powdered form).. 0,2m! HUP was added drop ise to the dry constituents and thoroughly mixed by hand with a spatula to form a loosely cohesive mass. Five drops of deionised water were then added with further mixing to produce a mouidabie putty. This was packed and compressed into the mould and then pushed out into deionised water. The sampie quickly hardened to form a porous cylindrical plug. The sampie was stored in deionized water at 3?*C and tested in compression as described in Example 1. Compression testing gave a peak stress of 0.5MPa.

Example 7

1 ml TCP was mixed with 0.2ml powdered PDLGA (50:50). 0.15ml ivlP was added dropwise to the dry constituents and thoroughly mixed by hand with a spatula to form a loosely cohesive mass. Five drops of deionised water were then added with further mixing to produce a mouldabie putty. This was packed and compressed into the mouid and then pushed out into deionised water. The sample quickly hardened to form a porous cylindrical plug. The sample was stored in deionized water at 37*C and tested in compression as described in Example 1. Compression testing gave a peak stress of i .25 Pa.

Example 8

1ml TCP was mixed with 0.1 ml powdered PDLGA (50:50), 0,15m! NMP was added dropwise to the dry constituents and thoroughly mixed by hand with a spatuia to form a loosely cohesive mass. Five drops of deionised water were ihen added with further mixing to produce a mouldab!e putty. This was packed and compressed into the mould and then pushed out into deionised water. The sample quickly hardened to form a porous cylindrical plug. The sample was too friable to undergo compression testing. Example 9

0,5ml TCP granules were combined with 0,5ml hydroxyapatite granules (2-3 mm -^■ supplied by Plasma Siotal Ltd}} and 0,2ml powdered POLGA (50:50). 0.25 ml HUP was added dropwise to the dry mixture and thoroughly mixed with a spatula, The further addition of 5 drops of deionised water produced a cohesive putty that was packed into the mould and then released out into deionised water, The sample quickly hardened to form a porous cylindrical plug. The sample was too friable to undergo compression testing, Example 10

0.4m! TCP granules were combined with 1.2ml hydroxyapatite granules (2-3 mm) and 0.8ml powdered PDLGA (50:50). 0,25 ml HMP was added dropwise to the dry mixture and thoroughly mixed with a spatula, The further addsilon of 5 drops of deionised water produced a cohesive putty that was packed into the mould and then released out into deionised water. The sample quickly hardened to form a porous cylindrical plug. The sample was stored in

deionized water at 37^eC and tested in compression as described in Example 1 , Compression testing gave a peak stress of 0.9MPa.

Compression Testing of Example 10

30

Com essive Strairi (%) Example 1 1

1ml of TCP was mixed with 0,25ml of PDLGA (85: 15). 1ml of ε-capfofactone (supplied by Acros Organics) was then dded and vSttrred to form a flowable mass. The maieriai was packed into the mould and 1 mi of water was added, The plug eou!d then be pushed out of the mould into deionized water. After about 5 minutes the sampie was removed and examined, it was a cohesive porous cylinder but still quite soft; if had fully hardened after 16 hours. The sampie was stored in deionized water at 37^eC and tested in cornprsssion as described in Example 1 . Compression testing gave a peak stress of O.SfV Pa.

Compression Testing of Exampie 11

Com ressive Strain {%}

Example 12

1 ml TCP was mixed with 0.25ml PDLGA 85:15 and then 0.98g NMP was added. The mixture was stirred to form a mouldable mass and was then packed into a cylindrical mould (internal diameter ~ 8.5mm) and compressed using f inger pressure. The plug of materia! was pushed out Into deionized water and was seen to harden instantly on contact with the water. The sample was stored irVdeionized water for 2 houfs and then removed and air dried.

The sample was prepared for icroCT anaiysis by mounting the bone void filler specimen directly onto a brass pin sample holder using an adhesive tab on the base of the bone void filler, Micro-CT images were acquired on a Skyscan 1173 Micro-CT using a micro focused X-ray source wit a voltage of 85kV and a current of 68μΑ, X-ray shadow images were acquired with a 0,4 deg step size over a 180 deg: acquisition angle, with 4 averages and βμπ* resolution. The X- ray shadow images were reconstructed into a stack of 2D cross-sections using a reconstruction program (N-Recon) supplied by Skyscan, The icro^»CT images were reconstructed using a smoothing factor of 2, a ring artefact correction of 12 and a beam hardness correction factor between 50%-65%. The results from the micro-CT scanning were as follows:

The sample was then tested in compression using an jnstron 5569 Universal testing Machine at a rate of 2.5mm/min, The sample had a compressive modulus of 2.33 Pa and a failure stress of 0.13MPa.

Example 13

tmf TCP was mixed with 1 ml FDLGA 85:15 and then Q,5g NMP was added. The mixture was stirred- to form a rnouldabte mass and was then packed into a cylindrical mould (internal diameter ~ 8.5mm) and compressed using finger pressure. The plug of material was pushed out into deionized water and was seen to harden instantl on contact with the water.

The sample was stored in deionized wafer for 24hours and then removed and air dried.

The sample was analysed by micro-CT as described in Example 12. The results from the micro-CT scanning were as follows:

The sample was then tested in compression as described in Example 12. The sample had a compressive modulus of 77.QMP& and a failure stress of

3.78MPa.

Example 14

2ml (-2.13g) HA granules (2-3mm, Plasma Biota!) was mixed with 0..24g PDLGA 85:15 and then 0,49g NMP was added. The mixture was stirred to dissolve the polymer and coat the ceramic particles. This formed a mouldable mass which was then packed into a cylindrical mould (internal diameter ~ 1 .8mm) and compressed using finger pressure. The plug of material was pushed out into delonized water and was seen to harden instantly o contact with the water.

The sample was stored in desonized water for 24hours and then removed and air dried.

The sarnpSe was analysed by micro-CT as described in Example 12. The results from the micro-CT scanning were as follows;

% Open Pore Space | 4!8

% Closed Pore Space

Total % Pore Space 141.9

% Material I 58,1

The sample was then tested in compression as described in Example 12. The sample had a compressive modulus of 1 SMPa and a failure stress of Q, 14 Pa. Example 15

0.1 g PDLGA 85; 16 was mixed with 0.37g NMP to dissolve the polymer. 2ml (~2.12g) HA granules (2-3mm, Plasma Biotal) was then mixed into the polymer solution. The mixture was stirred coat the ceramic particles. This formed a mouldab!e mass which was then packed into a cylindrical mould (internal diameter ~ 1 1 ,8mm) and compressed using finger pressure. The plug of materia! was pushed out into deionized water and was seen to harden instantly on contact with the wafer.

The sample was stored in deionized water for 24 ours and then removed and air dried,

The sample wa analysed by micn>CT as described in Example 1 . The results from the micro-GT scanning were as follows:

I % Open Pore Space j 39.7 |

% Closed Pore Space

Total % Pore Space

% Material 60.2

The sample was then tested in compression as described in Example 12. The sample had a compressive modulus 3.21 and a failure stress of Q,l8 Pa.

Example 16

A 33.3% w/w solution of PLGA 85:15 in NSVIP was prepared by mixing 3g PDLGA with 8g N P and allowing to stand overnight at room temperature until the polymer was fully dissolved.

4rnS (=1 ,48g) HA/TCP granules (0.8-1.5mm, supplied by Ceramssys Ltd) was mixed with G.52g of the 33.3% PDLGA solution and stiffed thoroughly to coat the granules. The resulting mass was packed into a cylindrical mouid (internal diameter ~ 1 ! ,8mm) and compressed using finger pressure. The plug of material was pushed out into deiGnked wafer and was seen to harden instantly on contact with the water. The sample was stored in desonlzed water tor 3- days and then removed and afr dried.

The sample was analysed by micro-CT as described in Example 12, The results from the micro-CT scanning were as follows:

The sample was then tested in compression as described in Exampte 12, The sample had a compressive modulus of 3,96 Pa and a failure stress of

0.24 Pa. Example 1?

2ml (»2.18g) HA granules {2^»3mm, plasma Biota!) was mixed with 0.53g of the 33,3% PDLGA ^: solution used in Example 16 and stirred thoroughly to coat the granules. The resulting mass was packed into a cylindrical mould {internal diameter = 1 ,8mm) and compressed using finger pressure. The plug of material was pushed out into deionized water and was seen to harden instantly on contact with the water.

The sample was stored in deionized wafer for 3 days and then removed and air dried,

The sample was analysed b micro-CT as described in Example 12. The results from the micro-CT scanning were as follows:

% Open Pore Space 42.9

% Closed Pore Space 0,0

Total % Pore Space 42.9

% Material 57,1

The sample was then tested in compression as described in Example 12. The sample had a compressiv modulus of l3,3MPa and a failure stress of 0.37MPa.

Example 18

2ml (-2,12g) HA granules {2^«3mm, plasma Biota!) was mixed with OJOg of the 33.3% PDLGA solution used in Example 16 and stirred thoroughly to coat the granules. The resulting mass was packed Into a cylindrical mould (internal diamete « 11 ,8mm}^' and compressed using finger pressure. The plug of material was pushed out into deionized water and was seen to harden instantly on contact with the wafer. The sample was stored in deionized water for 24 hours and then removed and air dried. The sample was analysed by miero-CT as described in Example 12. The results from the micro-CT scanning were as follows;

The sampte was then tested in compression as described in Example 12, The sampie had a compressive modulus of 31 ,5MPa and a failure stress of 1.52MPa.

Example 19

2ml (~0.72g) HA/TCP granules (0,8-1 ,5mm, Ceramisys) was mixed with 2ml (~1 ,72g) sucrose, then further mixed with 0.70g of the 33.3% PDLGA solution used in Example 1 Θ and stirred thoroughly to coat the granules. The resulting mass was packed into a cylindrical mould (interna! diameter = t 1 Jmm) and compressed using finger pressure. The plug of material was pushed out into deionized water and was seen to harden instantly on contact with the water but with some shedding of ceramic particles. The sucrose was also seen to dissolve, creating pores.

The sample was stored in deionized water for 24 hours and then removed and air dried.

The sample was analysed by micro-OT as described in Example 1 . The results from the micro-CT scanning were as follows:

% Open Pore Space 55.3

% Closed Pore Space 0.5

Total % Pore Space 55,8

% Material 44,2

i

The sampie was then tested in compression as described in Example 12. Th sample had a compressive modulus of 6,07 Pa and a failure stress of 2.13 Pa.

Example 20

2.5ml PDLGA 85:15 granules (as received - not cryo-mi!led) was mixed with 0.32g NMP. The NMP made the polymer granules tacky so that a mouidable cohesive mass was formed. This was packed Into a cylindrical mo ld (Internal diameter ~ 11 ,8mm) and compressed using finger pressure. The plug of material was pushed out into deionized water and was seen to harden instantly on contact with the water.

% Open Pore Space 37.7

% Closed Pore Space 572 j

Total % Pore Space 37.9

% Material

The sample was then tested in compression as described in Exampie 12. The sample had a compressive modulus of 26.5MPa and a failure stress of

3,65 Pa.

Exampie 1

1.25m! POLGA 85:15 granules (as received - not cryo-milied) was mixed with

I , 25ml HA/TCP (0.8-1 -5mm, Ceramisys) and further mixed with 0.33g NMP. The NMP made the polymer granules tacky so that a mouldable cohesive mass was formed. This was packed into a cylindrical mould (internal diameter ~

I I , 8mm} and compressed using finger pressure. The plug of material was pushed out into deionized water and was seen to harden instantly on contact with the water. There was some shedding of ceramic particles from the surface when the plug was dispensed into water.

The sample was stored in deionized water for 24 hours and then removed and air dried. The sample was analysed by micro-CT as described in Example 12, The results from the micro-CT scanning a s as follows:

The sample was then tested in compression as described in Example 12, sample had a compressive modulus of 0.97MPa and a failure stress of G.16MP& Table 1 below summarises the compositions and results from: Examples 1 -11

Table 2 below summarises the compositions from Examples 12-2

Table 3 below summarises the testing results from Examples 12-21 .

The resulis in tables 1 and 3 show thai materials able to wtthstand stresses up to 5MPa or higher are achievable, while still maintaining a high level of porosity.: Th compressive strength of cancellous bone is typically in the range 2-12 Pa so it can be seen that it is possible to make bone void filling materials with strengths in this range (Examples 1 , 2, 13, 19 and 20). The Young's modulus of cancellous bone is typically in the range 4-350lv1Pa and it can also be seen that it is possible to make materials with compressive moduli in this range (Examples 13, 16, 17, 18, 19, 20), Ail the samples had a high degree of porosity (20*60%) as seen in Table 3 and importantly most of this is

interconnected porosity with only very Sow levels of closed por space, thus allowing bone in-growth throughout the materia!. Inclusio of a parogen (such as in Example 19} can be seen to increase the porosity.

Claims

CLAIMS:

1. An implant material for bone void filling comprising bioresorbable

polymer granules and a biocompatible water-in iscibSe solvent, wherein the solvent at least partially dissolves and/or softens the polymer granules to form a mouldable mass that can be used to fi!l a bone defect but which hardens when the implant materia! is exposed to water, and wherein the implant material has macroporosity suitable for bone in- _. growth.

2. An implant materia! according to claim 1 comprising pores of between about 50 and 3000 microns; preferably 100 and 2000 microns; more preferably 120 and 1500 microns, which pores provide a macroporosity level suitable for bone in-growth,

3. An implant material according to claim 1 or claim 2, wherei the

bioresorbable polymer granules comprise particles, flakes or powder.

4. An implant materia! according to any one of claims 1 to 3, wherein the implant material further comprises a bioceramic material.

5. An implant material according to claim 4, wherein the bioceramic

material is formed as a mixture or dispersion with the bioresorbable polymer.

6. An implant material according to claim 4 or claim 5, wherein the

bioceramic material is porous and comprises granules, flakes or powder.

An impiant material according to any one of claims 4 to 6, wherein the bioceramic material comprises pores of between about 10 and 1000 microns; preferably 15 and 500 microns; more preferably 20 and 300 microns.

An implant material according to any one of the preceding claims, wherein the bioresorbable polymer granules include a core formed of a different materia!.

9. An implant materia! according to claim S, wherein the core is formed from a bioceramic materiai. 10. An impiant materiai according to claim 8, wherein the core includes an inner core and an outer core, and wherein the inner core is formed from a bioceramic material and the outer core comprises a second

bioresorbabie poiymer, 11.An implant materiai according to claim 10, wherein the outer core further comprises a bioactive or therapeutic agent.

12. An impiant material according to any on of claims 1 to 10, wherein the implant materiai comprises a bioactive or therapeutic agent.

13. An impiant materiai according to claim 12, wherein the first bioresorbabie polymer further comprises the bioactive or therapeutic agent.

14. An impiant material according to any one of claims 11 to 13, wherein the bioactive or therapeutic agent comprises at least one of: a growth factor such as any bone morphogenic protein (BMP), plateiet derived growth factor (PDGF), growth hormone, transforming growth factor-beta (TGF- beta), insulin-iike growth factor; a bone anabolic agent such as parathyroid hormone or teriparatide; an antkesorptive agent such as a bisphosphonate (including etidronate, ctodronate, tiludrortate, pamidranate, neridronate, olpadronate, alendronate, ibandronate, risedronate, zoledronate)_!or strontium ranelate; an antibiotic such as gentamicin, vancomycin, tobramycin, erythromycin, ciind amies n; an anticancer drug such as paclitaxe!, mercato urine; an anti-inflammatory and/or analgesic agent such as acetylsa!icyiic acid, ibuprofen, naproxen jndomethacine, ketoprofen or diciofenac.

15. An impiant materiai according to claim 10 or claim 11, wherein the

second bioresorbabie polymer is less soluble in the biocompatible solvent than the first bioresorbable poiyme .

16. An implant material according to any one of the preceding claims, wherein the bioceramtc material comprises at least one of: calcium phosphate, including hydroxyapatite, a substituted hydroxyapatite (e.g. silicon, carbonate, magnesium, strontium, fluoride), tricalcium

phosphate, biphasic calcium phosphate, tetracalcium phosphate, octaca!cium phosphate, dicaicium phosphate dihydrate (brushite), dicaicium phosphate (monetite), calcium pyrophosphate, caicium pyrophosphate dihydrate, heptacalcium phosphate, calcium phosphate monohydrate; calcium sulphate; a bioactive giass or glass ceramic.

17. An implant material according to any one of the preceding claims,

wherein the first bioresorbable polymer comprises at least one of: a polymer comprising a poly-alpha-hydroxyacid group, including poly(iacttc acid), poly{glycolic acid), pofy-L-Sactide, poiy-DL-iactide, poly(iactide~co- glycolide), poly(!actide-co-caprolactone), po!y(L-lactide-co~DL~lacttde)_! polycaproiactone; a bioresorbable polyanhydride, polyamide,

poiyorthoesfer, poiydioxanone, polycarbonate, polyaminoacid, poly(amino-ester), po!y(amido~carbonate), polyphosphazene, polyether, polyurethane, or po!ycyanoacrylate.

18. An implant material according to any one of the preceding claims,

wherein the second bioresorbable polymer comprises at least one of; a polymer comprising a po!y-alpha-hydroxyacid group, including poiy{lactic acid), poly(giyco!ic acid), poiy-L-lactide, poly-Dl-lactide, poiy(Sacttde~co~ glycoiide), poly(Sactide~co-capro!aotone), poly(L-lactide-co-DL-lactide), polycaproiactone; a bioresorbable polyanhydride, polyarnide,

poiyorthoesfer, polydioxanone, polycarbonate, polyaminoacid, poiy(amino-ester), poly(amido-carbonate), polyphosphazene, polyether, polyurethane, polycyanoacrylate; a polysaccharide comprising alginate, chitosan, carboxymethyl cellulose, hyd roxypropyimethy ! cellulose, dextran, or hyaluronic acid. 9. An implant material according to any one of the preceding claims, wherein the biocompatible, water miscible solvent comprises at least one of: N-methyl-pyrollidone, dimethyl sulphoxide, acetone, polyethylene glycol), tetrahydrofuran, isopropanol, or caprolactone.

20. An implant material according to any one of the preceding claims,

wherein the implant materiai includes a water soluble porogen that is not soluble in the biocompatible solvent.

21. An implant material according to claim 20, wherein the water soluble porogen. comprises at least one of: a soluble inorganic salt such as sodium chloride, calcium chloride, strontium chloride, magnesium chloride, a soluble organic compound such as sucrose, glucose, lactose, calcium gluconate, calcium iactate; or a water soluble polymer such as poly (ethylene glycol), polyethylene oxide), poly (ethylene oxide-b- propylene oxide), polyvinyl alcohol), poiy vinyl acetate, polyacrylic acid, poly vinyl pyrrolldone, poly(viny! phosphonic acid), polysaccharide such as carboxymethylceHu!ose, sodium alginate, chitosan, or dextran.

22. An implant material according to any one of the preceding claims,

wherein the implant material has an open porosity of greater than 15%.

23, An implant material according to claim 22, wherein the implant material has an open porosity of between about 15%-70%; more preferably about 20%-55%; most preferably about 25%-45%.