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Binder-free fabrication of copper-doped hydroxyapatite scaffolds by Powder Bed Laser Sintering
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DOI：10.1016/j.oceram.2026.100995.png)
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Abstract
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Additive manufacturing, particularly Powder Bed Laser Sintering (PBLS), offers promising routes for producing customized bioceramic scaffolds. However, direct shaping of hydroxyapatite (HAp) remains challenging due to its high melting point, low thermal conductivity, and the need for binder-free densification. In this study, a biphasic powder combining micrometric HAp and nanometric copper-doped HAp was developed to enhance laser absorption and enable localized sintering under near-infrared irradiation. The nano-phase selectively absorbs energy, promoting fusion while preserving the structural role of the micro-phase. Process parameters (laser power, scan speed, focalization) were optimized to fabricate cohesive ribbons and multilayer 3D scaffolds with controlled macroporosity (∼500 µm). Thermochromic changes of Cu-doped HAp indicated sintering, while microstructural analyses confirmed interlayer bonding. Despite concave deformations linked to thermal gradients, stable structures were obtained. Post-sintering treatments improved mechanical integrity, demonstrating the feasibility of binder-free PBLS for fabricating structurally controlled HAp scaffolds for bone regeneration.
Keywords:
Apatite
Sintering
Ceramic scaffolds
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