Three-dimensionally Perforated Calcium Phosphate Ceramics

Porous calcium phosphate ceramics were produced by compression molding using a special mold followed by sintering. The porous calcium phosphate ceramics have three-dimensional and penetrated open pores 380-400 μm in diameter spaced at intervals of 200 μm. The layers of the linear penetration pores alternately lay perpendicular to pore direction. The porosity was 59%-65%. The Ca/P molar ratios of the porous calcium phosphate ceramics range from 1.5 to 1.85. A binder containing methyl cellulose was most effective for preparing the powder compact among vinyl acetate, polyvinyl alcohol, starch, stearic acid, methyl cellulose and their mixtures. Stainless steel, polystyrene, nylon and bamboo were used as the long columnar male dies for the penetrated open pores. When polystyrene, nylon and bamboo were used as the long columnar male dies, the dies were burned out during the sintering process. Using stainless steel as the male dies with the removal of the dies before heat treatment resulted in a higher level of densification of the calcium phosphate ceramic.