Abstract The present study reports the manufacturing of a novel type of porous calcium phosphate scaffolds with elongated gyroid structures using digital light processing (DLP), in order to offer significantly enhanced mechanical properties. In particular, solid camphor was employed as the diluent, in order to offer sufficiently low viscosity at high solid loading for conventional layer-by-layer DLP process. Four types of porous CaP scaffolds with different percent elongation (%EL = 0, 20, 40, and 60) were manufactured, and their porous structures and mechanical properties were characterized. All porous CaP scaffolds showed that CaP walls were elongated along the z-direction, while the degree of pore elongation increased with an increase in the designed %EL. Owing to the use of controlled processing parameters, such as layer thickness and exposure time for layer-by-layer photocuring process, and carefully designed debinding process, the photocured layers could be completely bonded together with high densification after sintering at 1,200 °C for 3 h. Such elongation of a gyroid structure offered significantly enhanced mechanical properties − compressive strengths of 4.33 ± 0.26 MPa and 11.51 ± 1.75 MPa were obtained for the porous CaP scaffold with the %EL of 0 and 60, respectively.

中文翻译：

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通过使用数字光处理构建细长的陀螺结构来改善多孔磷酸钙支架的机械性能

摘要 本研究报告了使用数字光处理 (DLP) 制造具有细长螺旋结构的新型多孔磷酸钙支架，以提供显着增强的机械性能。特别是，固体樟脑被用作稀释剂，以便在高固体负载下为传统的逐层 DLP 工艺提供足够低的粘度。制造了四种具有不同伸长率 (%EL = 0、20、40 和 60) 的多孔 CaP 支架，并对它们的多孔结构和机械性能进行了表征。所有多孔 CaP 支架都显示 CaP 壁沿 z 方向伸长，而孔伸长程度随着设计的 %EL 的增加而增加。由于使用受控的加工参数，如层厚和曝光时间等逐层光固化工艺，以及精心设计的脱脂工艺，在1200℃下烧结3小时后，光固化层可以完全粘合在一起并具有高致密性。陀螺结构的这种伸长提供了显着增强的机械性能 - 对于 %EL 分别为 0 和 60 的多孔 CaP 支架，获得了 4.33 ± 0.26 MPa 和 11.51 ± 1.75 MPa 的压缩强度。