Prosthesis loosening due to lack of osteointegration between an implant and surrounding bone tissue is one of the most common causes of implant failure. Further, bacterial contamination and biofilm formation onto implants represent a serious complication after surgery. The enhancement of osteointegration can be achieved by using bioconductive materials that promote biological responses in the body, stimulating bone growth and thus bonding to tissue. Through the incorporation of antibacterial substances in bioconductive, biodegradable calcium phosphate (CaP) coatings, faster osteointegration and bactericidal properties can be achieved. In this study, Cu-doped CaP supraparticles are spray-dried and suspension-sprayed CaP ceramic coatings with antibacterial properties are prepared using high-velocity suspension flame spraying (HVSFS). The objective was to increase the coatings’ porosity and investigate which Cu-doped supraparticles have the strongest antibacterial properties when introduced into the coating layers. Biocompatibility was tested on human Osteosarcoma cells MG63. A porosity of at least 13% was achieved and the supraparticles could be implemented, enhancing it up to 16%. The results showed that the addition of Cu-doped supraparticles did not significantly reduce the number of viable cells compared to the Cu-free sample, demonstrating good biocompatibility. The antimicrobial activity was assessed against the bacterial strains Escherichia coli and Staphylococcus aureus, with Safe Airborne Antibacterial testing showing a significant reduction in both Gram-positive and Gram-negative strains on the Cu-doped coatings.

This work highlights the potential of porous, bioactive coatings to advance implant technology and address critical clinical challenges. A key issue in implant coatings is to achieve the balance between infection prevention and successful osseointegration. Although titanium implants are widely used due to their mechanical strength and biocompatibility, their bioinert nature limits integration with bone tissue. To address these issues, porous calcium phosphate (CaP) coatings have been developed to enhance cell attachment and bone growth. However, CaP, especially in the widely used form of hydroxyapatite (HAp), has a low resorption rate, which often leads to prolonged coating stability and impairs natural bone remodeling. To overcome this limitation, magnesium phosphate (MgP), an underexplored but promising biomaterial with high biocompatibility and osteogenic potential, can be introduced. Another innovative strategy is the doping of biomaterials with antibacterial ions, among which copper (Cu) has attracted particular attention. The incorporation of Cu into the coating matrix can significantly reduce the risk of post‐operative infection while promoting angiogenesis, a key factor for rapid and stable implant integration. This study presents bone implant coatings composed of tricalcium phosphate (TCP) and Cu‐doped MgP clustered nanoparticles (supraparticles) fabricated via high‐velocity suspension flame spraying (HVSFS). This particle system addresses current challenges in bone tissue regeneration by synergistically combining the high biodegradability of MgP, the bone‐mimicking properties of CaP, and the antibacterial capabilities of Cu. In addition, the HVSFS process enables the creation of thin layers with porous microstructures. Biocompatibility of the prepared coatings was assessed using MG63 osteosarcoma cells, while the antibacterial efficacy was tested against Staphylococcus aureus and Escherichia coli . The incorporation of Cu‐doped MgP supraparticles (MgPCu and MgPCu HT) into TCP coatings resulted in high Cu release and pronounced antibacterial efficacy compared to the TCP reference, while the addition of Cu‐doped FT supraparticles (FTCu) led to high cell proliferation.

Implant–associated infections and aseptic loosening of prosthesis due to insufficient secondary stability continue to present a challenging issue in arthroplasty. Potential solutions include bioactive coatings to promote osseointegration. With this in mind, this study aims to investigate and compare thin bioactive and bioresorbable β-tricalcium phosphate (β-TCP) and calcium alka-li orthophosphate (GB14) coatings, both produced via high velocity suspension flame spraying. To achieve an additional antibacterial effect and to prevent infections through aerosolized contamination, Cu-doped β-TCP supraparticles (SP) are incorporated into the coatings. β-TCP and GB14 coatings with 0.5 wt.% Cu-doped β-TCP SP each were investigated. According to ISO EN 10993–14, a degradation test was performed in TRIS-buffer at pH 7.4 over 120 h. Biocompatibility testing was performed on human osteoblasts using live/dead staining on days 1, 3 and 7 to simultaneously visualize viable and non-viable cells, while cytotoxicity was assessed over a 3 d period with the cytotoxicity assay. To evaluate the antibacterial efficacy, safe airborne antibacterial assays using S. aureus and E. coli were performed. Our investigations demonstrate that Cu is released from the coatings over a period of 120 h. The released Cu-amount results in a significant reduction in colony forming units across all coatings, while only negligibly imparing the behavior of the human osteoblasts. Both coatings exhibit high biocompatibility, with cell counts varying depending on the amount of Cu released. Cytotoxicity testing showed no cytotoxic effects for the samples examined.

The present study investigates the effect of thin porous ceramic coatings on implant stability, focusing on two materials: a calcium alkali orthophosphate (GB14, Ca ₂ KNa(PO ₄ ) ₂ ) and β-tricalcium phosphate (β-TCP), with and without copper (Cu) incorporation. The coatings were applied to titanium implant surfaces (CP Ti, grade 2) and characterized for porosity and microstructure. The in vivo performance of the material is assessed in a New Zealand White rabbit model. Following defined healing periods, biomechanical push-out testing were performed. The results of β-TCP/Cu for cancellous bone show that Cu-doped coatings exhibit significantly improved bone integration compared to their Cu-free counterparts. The enhanced fixation is attributed to the bioactive and potential antibacterial properties of copper, which may stimulate osteogenesis and the presence of supraparticles in the Cu samples. Furthermore, the incorporation of β -TCP supraparticles into the ceramic matrix increases overall coating porosity, facilitating deeper bone ingrowth and improved mechanical interlocking. This structural change results in improved osseointegration compared to less porous coatings. This structural change results in improved osseointegration compared to less porous coatings. The results of this study demonstrate that combining copper incorporation with enhanced porosity through supraparticles can improve implant stability by shortening the time required for the transition from primary to secondary stability. This approach offers a promising strategy for optimizing surface design in orthopedic and dental implants.