Fabrication of porous hydroxyapatite bodies by a new direct consolidation method: starch consolidation.

A new direct consolidation method known as "starch consolidation" was developed especially for the fabrication of porous ceramics, as adopted to prepare hydroxyapatite (OHAp) bodies with different pore sizes and pore volume fractions. The method is based on the swelling ability of starch when it is heated to 80 degrees C in the presence of water. An OHAp powder prepared by a precipitation method and heat treated at 900 degrees C to obtain an appropriate specific surface area for colloidal processing was used in the present work. Wet ball milling was required to deagglomerate the powder and improve its processing ability. Different starch volume fractions and starch particle sizes were added to the OHAp slurries, which were then heat treated to promote consolidation by starch gelification. A linear relationship between the planned and measured porosity values was observed. SEM pictures reveal the presence of interconnected pores with shape and sizes corresponding to starch granules used. Flexural strength varied from about 2 to 15 MPa, for pore volume fractions of approximately 70 and 45%, respectively. A degradation study in an acellular synthetic body fluid (SBF) has shown that the prepared bodies keep their integrity under physiological conditions during the studied time. The method offers possibilities of manufacturing materials that can be used as scaffolds engineering and/or systems for controlled delivery of drugs. Copyright 2002 John Wiley & Sons, Inc. J Biomed Mater Res 60: 232--240, 2002; DOI 10.1002/jbm.10036