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In this work we present a novel algorithm for generating in-silico biomimetic models of a cortical bone microstructure towards manufacturing biomimetic bone via additive manufacturing. The software provides a tool for physicians or biomedical engineers to develop models of cortical bone that include the inherent complexity of the microstructure. The correspondence of the produced virtual prototypes with natural bone tissue was assessed experimentally employing Digital Light Processing (DLP) of a thermoset polymer resin to recreate healthy and osteoporotic bone tissue microstructure. The proposed tool was successfully implemented to develop cortical bone structure based on osteon density, cement line thickness, and the Haversian and Volkmann channels to produce a user-designated bone porosity that matches within values reported from literature for these types of tissues. Characterization of the specimens using a Scanning Electron Microscopy with Focused Ion Beam (SEM/FIB) and Computer Tomography (CT) revealed that the manufacturability of intricated virtual prototype is possible for scaled-up versions of the tissue. Modeling based on the density, inclination and size range of the osteon and Haversian and Volkmann´s canals granted the development of a dynamic in-silico porosity (13.37–21.49%) that matches with models of healthy and osteoporotic bone. Correspondence of the designed porosity with the manufactured assessment (5.79–16.16%) shows that the introduced methodology is a step towards the development of more refined and lifelike porous structures such as cortical bone. Further research is required for validation of the proposed methodology model of the real bone tissue and as a patient-specific customization tool of synthetic bone.

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In this work, we assess the effects of sterilization in materials manufactured using additive manufacturing by employing a sterilization technique used in the food industry. To estimate the feasibility of the hydrostatic high-pressure (HHP) sterilization of biomedical devices, we have evaluated the mechanical properties of specimens produced by commercial 3D printers. Evaluations of the potential advantages and drawbacks of Fused Deposition Modeling (FDM), Digital Light Processing (DLP) technology, and Stereolithography (SLA) were considered for this study due to their widespread availability. Changes in mechanical properties due to the proposed sterilization technique were compared to values derived from the standardized autoclaving methodology. Enhancement of the mechanical properties of samples treated with Hydrostatic high-pressure processing enhanced mechanical properties, with a 30.30% increase in the tensile modulus and a 26.36% increase in the ultimate tensile strength. While traditional autoclaving was shown to systematically reduce the mechanical properties of the materials employed and damages and deformation on the surfaces were observed, HHP offered an alternative for sterilization without employing heat. These results suggest that while forgoing high-temperature for sanitization, HHP processing can be employed to take advantage of the flexibility of additive manufacturing technologies for manufacturing implants, instruments, and other devices.

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