Bioactive glasses have been used for many years in the human body as bone substitute. Since bioactive glasses are not readily available in the form of endless thin fibres with diameters below 20 µm, their use is limited to mainly non-load-bearing applications in the form of particles or granules. In this study, the spinnability of four bioactive silicate glasses was evaluated in terms of crystallisation behaviour, characteristic processing temperatures and viscosity determined by thermal analysis. The glass melts were drawn into fibres and their mechanical strength was measured by single fibre tensile tests before and after the surface treatment with different silanes. The degradation of the bioactive glasses was observed in simulated body fluid and pure water by recording the changes of the pH value and the ion concentration by inductively coupled plasma optical emission spectrometry; further, the glass degradation process was monitored by scanning electron microscopy. Additionally, first in vitro experiments using murine pre-osteoblast cell line MC3T3E1 were carried out in order to evaluate the interaction with the glass fibre surface. The results achieved in this work show up the potential of the manufacturing of endless bioactive glass fibres with appropriate mechanical strength to be applied as reinforcing fibres in new innovative medical implants.

The use of bioresorbable fracture fixation plates made of aliphatic polyesters have good potential due to good biocompatibility, reduced risk of stress-shielding, and eliminated need for plate removal. However, polyesters are ductile, and their handling properties are limited. We suggested an alternative, PLAMA (PolyLActide functionalized with diMethAcrylate), for the use as the matrix phase for the novel concept of the in situ curable bioresorbable load-bearing composite plate to reduce the limitations of conventional polyesters. The purpose was to obtain a preliminary understanding of the chemical and physical properties and the biological safety of PLAMA from the prospective of the novel concept. Modifications with different molecular masses (PLAMA-500 and PLAMA-1000) were synthesized. The efficiency of curing was assessed by the degree of convergence (DC). The mechanical properties were obtained by tensile test and thermomechanical analysis. The bioresorbability was investigated by immersion in simulated body fluid. The biocompatibility was studied in cell morphology and viability tests. PLAMA-500 showed better DC and mechanical properties, and slower bioresorbability than PLAMA-1000. Both did not prevent proliferation and normal morphological development of cells. We concluded that PLAMA-500 has potential for the use as the matrix material for bioresorbable load-bearing composite fracture fixation plates.

This study introduces Amanita, a pioneering bionic design for a fully 3D-printed cranial implant made of polyether-ether-ketone (PEEK) functionalized with bioactive glass granules. The mechanical integrity of cranial implants is crucial for effective brain protection. The primary aim was to evaluate the mechanical resistance of this innovative implant to validate its functionality for cranial protection. We employed a standardized biomechanical testing protocol to assess the mechanical properties of the Amanita implants. The implants were subjected to impact forces that simulated real-life blunt trauma scenarios to test their performance under stress. The Amanita implants exhibited significant resilience under compressive forces, withstanding over 100 N at a 2 mm deflection and effectively absorbing more than 1000 mJ at a 6 mm deflection. Furthermore, these implants maintained structural integrity without catastrophic failure at deflections up to 10 mm. The findings validate the design and manufacturing approach of the Amanita implants, demonstrating their potential for clinical use in cranioplasty. The implants showed adequate impact resistance, potentially lowering the risk of injury from falling objects or blunt trauma. Additionally, the adoption of additive manufacturing techniques enables the production of these implants on-site at hospitals, promoting socially and environmentally sustainable healthcare solutions.

Fibre reinforced composites are attractive materials for hard tissue reconstructions, due to the high strength and low flexural modulus. However, lack of contourability in the operation theatre inhibits their clinical applications. The study presents a novel in situ contourable composite implant system for load-bearing conditions. The implant system consists of a thin bioresorbable shell with several cavities, much like bubble-wrap. The central cavity contains a semi-flexible glass fibre preform prepared using Tailored Fibre Placement method. The preform is either pre-impregnated with a light curable resin, or the resin is injected into the cavity during the surgical procedure, followed by light curing. The semi-flexible glass fibre preforms were also examined as separate devices, "miniplates". Two types of miniplates were scrutinized, a simplified pilot design and a spatially refined, "optimized" design. The optimized miniplates were implemented as biostable and bioresorbable versions. The feasibility of the in situ contourable composite implant system was demonstrated. The potential of Tailored Fibre Placement for the semi-flexible glass fibre preforms and miniplates was confirmed in a series of biomechanical tests. However, structural optimization is required. Antebrachial fractures in toy-breeds of dogs are exemplar veterinary applications of the devices; further applications in veterinary and human patients are foreseen.