3D-printed pyrolytic carbon scaffolds usher in a new era of bone regeneration; programmable biomaterials breakthroughs emerge

The research team at IMDEA Materials Institute has published a groundbreaking study in Small Structures, marking the first successful fabrication of an all-carbon bone scaffold using a combination of 3D printing and high-temperature pyrolysis. This innovative approach eliminates the need for traditional additives, achieves mechanical properties comparable to natural bone, and enables active regulation of cell growth.

The scaffolds were fabricated by the IMDEA Materials Institute using polyethylene glycol diacrylate (PEGDA)

Breakthrough Highlights:

The IMDEA Materials Institute team has, for the first time, developed all-carbon bone scaffolds through 3D printing combined with high-temperature pyrolysis, moving away from the reliance on conventional composite additives. These scaffolds match the mechanical properties of natural bone and actively guide cellular behavior.

Core Technical Approach:

Innovative Manufacturing Process:
  • UV-curing 3D printing of PEGDA (polyethylene glycol diacrylate) resin to form precise scaffold architectures
  • High-temperature pyrolysis at 800°C in an oxygen-free environment, converting the polymer into a pure carbon framework (with shrinkage rates of up to 80%)
  • This approach overcomes the limitations of traditional carbon materials that require polymer composites, enabling direct formation of pure carbon microlattices
Performance Tuning Strategy:

Programmable thermal gradient from 500–900°C allows control over scaffold properties:

  • High-temperature region (900°C): Enhanced conductivity, elastic modulus reaches 14 GPa, comparable to cortical bone
  • Low-temperature region (500°C): Increased oxygen-containing surface groups, promoting 1.9× cell proliferation

Maintains complex bone-mimicking porosity (~200 µm) with resolution exceeding conventional 3D printing techniques

Disruptive Advantage:

Four-Dimensional Adaptability: Simultaneously fulfills clinical requirements for:

  • Mechanical strength (~900 MPa compressive strength)
  • Geometric precision (<50 µm features)
  • Surface bioactivity (no bio-coatings needed)
  • Imaging compatibility (no MRI artifacts)

Dynamic Regional Control: Enables a single scaffold to feature differentiated thermal treatment in different zones:

  • Bone-growth zones with high cell activity
  • Load-bearing zones with reinforced mechanical strength

Industrialization Outlook:

This technology has been incorporated into the EU Marie Skłodowska-Curie 3D-CARBON Project, paving the way for clinical translation of biodegradable carbon-based bone implants. Compared to traditional metal implants (which risk stress shielding) or ceramics (which face machining limitations), this scaffold system offers precise bioadaptability, potentially ushering in a new era of “programmable biomaterials” in orthopedic repair. The team is currently collaborating with medical enterprises to develop customized bone repair solutions.

*This article originally appeared on VoxelMatters. Edward Wakefield is the original author of this piece.

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