Can we prevent cracks in 3D-printed ceramics before they even form?

Additive manufacturing, commonly known as 3D printing, has opened new possibilities for developing biomaterials intended for bone tissue regeneration. This technology enables the fabrication of complex three-dimensional structures with precisely controlled geometry and porosity. However, when it comes to ceramic materials, successful 3D printing is only the first step. The real challenge begins during subsequent thermal processing, when the printed structure must be transformed into a strong and stable ceramic material.

During sintering, a high-temperature process in which ceramic particles bond together, the printed structure undergoes shrinkage. If this process is not sufficiently uniform, deformation, microcracks, and other structural defects may develop, compromising the mechanical properties of the final product. These challenges are particularly pronounced in porous ceramic scaffolds intended for bone tissue regeneration.

The CaPES-3D project is based on the idea that the stability of 3D-printed ceramic structures can be improved by engineering the material itself, rather than relying solely on optimising printing and sintering conditions.

The research focuses on composites combining β-tricalcium phosphate (β-TCP), a bioceramic material chemically related to the mineral component of bone, with titanium-based nanowires (TiNW). Instead of conventionally mixing the two components, calcium phosphate will be synthesised in the presence of nanowires to achieve a more homogeneous distribution and stronger interfacial interactions within the composite.

These materials will be used to formulate ceramic pastes for extrusion-based 3D printing. The project will investigate how composite composition and microstructure influence printing accuracy, sintering behaviour, crack formation, and the mechanical stability of porous scaffolds. Their bioactivity, protein interactions, and biological response of bone cells, including primary human osteoblasts, will also be evaluated to assess their potential for biomedical applications.

The ultimate goal of CaPES-3D is not only to develop a new ceramic composite, but to understand how material design at the nanoscale influences the stability of complex 3D-printed structures. The knowledge gained could contribute to more reliable manufacturing of porous bioceramic scaffolds and provide a scientific foundation for future advances in bone tissue regeneration.

Project information

Research Team

Principal Investigator

• Dr. Ina Erceg

Research Team Members

• Dr. Suzana Inkret
• Dr. Irena Ivanišević
• Dr. Ana Ivančić
• Dr. Ivana Vrgoč Zimić