Macroporous hydroxyapatite as alloplastic material for dental applications

In the dentistry field, synthetic hydroxyapatite can be conveniently used as semiabsorbable alloplastic material to solve a number of clinical problems. The hydroxyapatite structure influences bone ingrowth as well as its resorption. In particular, pore size must exceed 100 μm to allow new bone ingrowth. Because of its brittleness, highly porous hydroxyapatite is difficult to handle without causing damage, and, therefore, its mechanical performance has to be improved placing the material on a dense hydroxyapatite substrate. Dense/porous hydroxyapatite laminates can be obtained by slip casting technology. The method starts with the preparation of a ceramic powder–binder–solvent system. This slurry produces, after solvent evaporation, a soft green tape, that is successively baked at 300 °C to remove all organic component, and finally sintered at high temperature (1200 °C). The material porosity cannot be significantly modified by changes in the slurry composition and sintering temperature; therefore, the macroporous hydroxyapatite layer must be obtained using a porous hydroxyapatite powder. The powder is prepared by grinding of green tape pieces and the resulting coarse material is successively baked at 300 °C. Such material is mixed with a polymer solution and cast on a green tape substrate. Layer fractures are not observed in both film bulks and interface, because during sintering the consolidation of two layers happens simultaneously. In the resulting material, the first layer consisted of macroporous hydroxyapatite with high osteoconductive properties, and the second layer was a dense hydroxyapatite substrate able to improve the laminate mechanical properties. © 1999 Kluwer Academic Publishers