3-d printing of bone grafts

Abstract

Computer implemented methods of producing a bone graft are provided. These methods include obtaining a 3-D image of an intended bone graft site; generating a 3-D digital model of the bone graft based on the 3-D image of the intended bone graft site, the 3-D digital model of the bone graft being configured to fit within a 3-D digital model of the intended bone graft site; storing the 3-D digital model on a database coupled to a processor, the processor having instructions for retrieving the stored 3-D digital model of the bone graft and for combining a carrier material with, in or on a bone material based on the stored 3-D digital model and for instructing a 3-D printer to produce the bone graft. A layered 3-D printed bone graft prepared by the computer implemented method is also provided.

1 - 13 . (canceled) 
     
     
         14 . A layered 3-D printed bone graft, the layered bone graft comprising:
 (i) a first layer of biodegradable polymer; a second layer of a bone material disposed on the first layer of biodegradable polymer; and a third layer of biodegradable polymer disposed on the second layer, each layer repeating until a 3-D printer has completed the layered bone graft; or   (ii) a first layer of biodegradable polymer mixed with the bone material; a second layer of biodegradable polymer mixed with the bone material, the second layer disposed on the first layer; and a third layer of biodegradable polymer mixed with the bone material, the third layer disposed on the second layer, each layer repeating until the 3-D printer has completed the layered bone graft.   
     
     
         15 . The layered 3-D printed bone graft of  claim 14 , wherein the bone material comprises (i) mineralized allograft bone, nondemineralized allograft bone or a combination thereof; or (ii) allograft bone, demineralized bone matrix fiber, demineralized bone matrix chips or a combination thereof. 
     
     
         16 . The layered 3-D printed bone graft of  claim 14 , wherein the bone material comprises (i) fully demineralized bone fibers and surface demineralized bone chips; or (ii) a demineralized bone matrix material comprising fully demineralized bone matrix fibers and surface demineralized bone chips in a ratio of from about 25:75 to about 75:25. 
     
     
         17 . The layered 3-D printed bone graft of  claim 14 , wherein the polymer comprises a curable polymer comprising at least one of poly(lactic acid), poly(glycolic acid), poly(lactic acid-glycolic acid), polydioxanone, PVA, polyurethanes, polycarbonates, polyhydroxyalkanoates (polyhydroxybutyrates and polyhydroxyvalerates and copolymers), polysaccharides, polyhydroxyalkanoates polyglycolide-co-caprolactone, polyethylene oxide, polypropylene oxide, polyglycolide-co-trimethylene carbonate, poly(lactic-co-glycolic acid) or combinations thereof. 
     
     
         18 . The layered 3-D printed bone graft of  claim 17 , wherein the polymer further comprises at least one of a polymer sugar, protein, hydrophilic block copolymer, hyaluronic acid, polyuronic acid, mucopolysaccharide, proteoglycan, polyoxyethylene, surfactant, polyhydroxy compound, polyhydroxy ester, fatty alcohol, fatty alcohol ester, fatty acid, fatty acid ester, liquid silicone, or combinations thereof. 
     
     
         19 - 20 . (canceled) 
     
     
         21 . A layered 3-D printed bone graft, the layered 3-D printed bone graft comprising a carrier material with, in or on a bone material, the carrier material comprising a curable ink containing microspheres having diameters from about 1 μm to about 750 μm in size, the carrier material and the bone material forming a mesh bag and a cover, the mesh bag being filled with a second bone material such that the mesh bag, the second bone material and the cover form the layered 3-D bone graft, the layered 3-D bone graft being configured to match a 3-D digital model of the bone graft including a virtual depth, thickness and volume of the bone graft fitting within a 3-D digital model of an intended bone graft site. 
     
     
         22 . The layered 3-D printed bone graft of  claim 14 , wherein the layered bone graft comprises a carrier material with the bone material; 
     
     
         23 . The layered 3-D printed bone graft of  claim 14 , wherein the layered bone graft is customized to an intended bone graft site. 
     
     
         24 . The layered 3-D printed bone graft of  claim 22 , wherein the bone material is printed in or on the carrier material. 
     
     
         25 . The layered 3-D printed bone graft of  claim 22 , wherein the carrier material comprises a metal, a biodegradable polymer or a combination thereof, and the bone material comprises mineralized or demineralized bone.