Enhancing mechanical performance of hydroxyapatite-based bone implants via citric acid post-processing in binder jetting additive manufacturing

Binder jetting is a promising technology in the additive manufacturing of bone implants, particularly for printing brittle bioceramics that are susceptible to thermal residual stresses. However, challenges in this field include low strength and undesirable size changes due to post-sintering treatments, as well as the absence of necessary organic matter like Glycosaminoglycans, citric acid, etc. To address these issues, a novel approach was introduced using citric acid (CA) as a post-processing agent to enhance the mechanical performance of green samples and add organic matter, with boric acid (BA) as a control. A hydroxyapatite (HA) based powder mixed with 25 wt.% high-viscosity polyvinyl alcohol (PVA) was prepared and printed using a self-made printer with deionized water as the binder. The post-processing effects were analyzed in terms of mechanical properties and microstructure. The application of 5 wt.% CA solution increased the thickness of the PVA film between HA particles by 320.0%, leading to an increase in compressive strength (7.37 ± 0.28 MPa) and modulus (102.81 ± 6.74 MPa) by 840.7% and 1571.3%, respectively, achieving the mechanical standards for human trabecular bone. This work presents a simple and rapid room-temperature post-processing strategy for enhancing the mechanical properties of bone implants produced by binder jetting additive manufacturing.