Abstract: Bone void filler pieces that are conducive to packing or nesting when a plurality of pieces are located in a cavity in random orientation. The bone void filler of the present invention includes a higher bulk packing density and a porosity of less than 80% to provide a better match native bone ingrowth rate. Further, the bone void filler includes a bi-modal pore distribution with a high frequency of smaller pores to enhance the density characteristic of the bone void filler pieces. A method of manufacturing the bone void filler pieces includes a precursor powder composition suitable to form a ceramic matrix; the preform is converted by chemical reaction to a final composition. The preform further includes the use of a porogen that decomposes to gaseous decomposition products upon heating.

Abstract: The invention includes a three-dimensional printing (3DP) machine that has at least one ultraviolet (UV) light source directed at powder or slurry being processed by the 3DP machine and/or directed at any of various surfaces or machine components, in a manner suitable to kill or damage microorganisms to a desired extent. The UV light sources may be either stationary or movable, and may be either pulsed or substantially continuous, and may operate in any desired sequence and timing with respect to other operations performed by the machine. The invention may include ultraviolet illumination in such a way as to interact with powder to sterilize or disinfect powder either while the powder is stationary or, alternatively, as powder is being moved from one place to another within the 3DP machine, or both. The invention also includes methods of performing three-dimensional printing using such illumination.

Abstract: An engineered regenerative biostructure (erb) for implantation into a human body as a bone substitute, which includes an internal microstructure, mesostructure and/or macrostructure to provide improved bone in-growth, and methods for making the erb. Under one aspect of the invention, the biostructure has resorbable and nonresorbable regions. Under another aspect of the invention, the biostructure is constructed of hydroxyapatite, tricalcium phosphate and/or demineralized bone. Under yet another aspect of the invention, the porous biostructure is partially or fully infused with a resorbable, nonresorbable or dissolvable material.

Abstract: A biostructure including a porous matrix, the interstitial pores of the matrix selectively infused with an interpenetrant such that portions of the matrix remain uninfused. The biostructure may include a ceramic matrix and a polymer interpenetrant. The biostructure may be an implantable bone substitute including a bone repair device, a cranioplasty device, a burr hole cover or cap, a mandibular repair device, other craniofacial repair device, an alveolar ridge augmentation, bone void filler, a spinal fusion or other spinal repair device, or other substitute for either a portion of a bone or an entire bone. The biostructure, or its corresponding matrix, may have dimensions which may be customized for a particular patient and which may be based on medical imaging data and may further include geometric features not present in the medical imaging data. The biostructure may be used in culturing cells outside the body of a patient.

Abstract: An engineered regenerative biostructure (erb) for implantation into a human body as a bone substitute, which includes an internal microstructure, mesostructure and/or macrostructure to provide improved bone in-growth, and methods for making the erb. Under one aspect of the invention, the biostructure has resorbable and nonresorbable regions. Under another aspect of the invention, the biostructure is constructed of hydroxyapatite, tricalcium phosphate and/or demineralized bone. Under yet another aspect of the invention, the porous biostructure is partially or fully infused with a resorbable, nonresorbable or dissolvable material.