Chemical mechanical vapor deposition device for production of bone substitute material

Abstract

A method for fabricating a substitute component for bone, including the processes of: provision of a chemical spray including at least three of calcium chloride, hydrogen phosphate, hydrogen carbonate and water to form a combined solution; reaction and precipitation of the combined solution onto a substrate; allowing the precipitated particles to form a porous structure on the substrate; applying substantially isostatic pressure to the porous structure to form a compressed structure; and (optional) providing one or more through-holes in the compressed structure to promote osteoinduction.

1 . A method for fabricating a substitute component for a bone, the method comprising:
 (i) providing a combined solution comprising at least two of: a first aqueous solution of calcium chloride, a second aqueous solution of hydrogen phosphate, a third aqueous solution of hydrogen carbonate and a fourth solution comprising distilled water;   (ii) allowing the combined solution to form and precipitate onto a substrate at least two particles, each particle having a diameter in a range between 500 nanometers (nm) and 20 micrometers (μm), and including at least one of hydroxyapatite, tricalcium phosphate, octacalcium phosphate and dicalcium phosphate dihydrate, where the substrate has a selected shape and is maintained in a chamber within a selected pH range and within a selected temperature range;   (iii) allowing the deposited precipitate particles to form a porous structure on the substrate having different selected thicknesses in at least two different regions of the substrate; and   (iv) applying substantially isostatic pressure to the porous structure to form at least one layer of a bone component.