Micro-porous calcium phosphate coatings on load-bearing zirconia substrate: Processing, property and application

This study presents the design, processing, properties and potential applications of a novel layered bio-ceramic composites consisting of three different micro-porous calcium phosphate coatings on strong zirconia cores manufactured using a recently developed slip coating-deposition and coating-substrate co-sintering technique. Detailed microstructures of the three graded micro-porous calcium phosphate coatings, and the coating/substrate interface have been investigated. Also, the flexural strength of the bio-ceramic composite and the bonding state between the coatings and zirconia substrate have been characterized. A preliminary and limited in vitro cell test indicates that the new scaffold composite has no cytotoxicity to the fibroblasts which can attach, proliferate and grow on the coating surfaces. Because of the combination of bio-function and strength, such layered load-bearing bio-ceramic composites are a potential candidate for large-scale head bone repairs.