Preliminary Considerations on the Design of Multi-layered Bone Scaffold for Laser-Based Printing

Abstract

Several implant materials are used in cranial surgery. Still, each one has its drawbacks, such as the risk of infections, low mechanical strength, or low osseointegration. Implants with a porous surface are considered more effective than a smooth and rough coating. The porosity density and structure also influence the mechanical properties of the final implant. Moreover, the implant properties depend on the manufacturing method. This study aims to present a custom-made cranial scaffold composed of two distinct layers. A compact inner one guarantees adequate structural properties to the scaffold. In contrast, a porous outer one lightens the scaffold structure and assures the correct osseointegration. The customized scaffold has been designed through a 3D free-form modeling system. It can be manufactured by 3D printing techniques such as direct metal laser sintering in titanium or via selective laser sintering using PEEK. The advantages and limitations of the multi-layered custom-made scaffold and the related design process are qualitatively described.