A novel strategy for fabricating zirconia implants with a trabecular biomimetic porous surface

For successful osseointegration of load-bearing implants, an improved bone–implant contact area through a trabecular porous surface resulting in minimized stress shielding effect is highly desirable. We propose a novel strategy of green net shaping a ceramic dough, combined with a reticular foam replica method and gradient coating, to fabricate biomimetic porosity in a customizable ceramic dental implant for the first time. About 85 vol% porosity and 300–600-μm pore size were evident in microCT and electron microscopy of the sintered samples, suitable for bone ingrowth. Excellent integrity at the interface along with homogeneous distribution of secondary alumina phase in zirconia matrix was achieved, despite the difference in the green state powder loading between the dough and the slurry.