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6 February 2026

Personalised 3D-Printed Bone Substitutes Advance Regenerative Medicine

Personalised 3D-Printed Bone Substitutes Advance Regenerative Medicine

A project developed at CICECO – the Institute of Materials of the University of Aveiro is opening new directions in regenerative medicine through the development of personalised bone substitutes produced by three-dimensional printing.

The investigation is being carried out by Simão Santos, a doctoral candidate at CICECO, with the participation of doctoral student Manuel Alves and Susana Olhero and Georgina Miranda, from the Department of Materials and Ceramic Engineering of the University of Aveiro.

The researchers are applying an additive manufacturing approach that enables the fabrication of patient-specific structures, tailored to the geometry and characteristics of the bone to be replaced. The technique, known as vat photopolymerisation, relies on a liquid resin that is solidified layer by layer under light exposure, resulting in solid ceramic components whose shape closely matches the clinical requirements of each case.

Mimicking Human Bone

A central element of the project is the use of hydroxyapatite, a biocompatible and bioactive ceramic that resembles the mineral phase of natural bone. The material is suspended in a water-based resin, allowing the production of complex architectures adapted to individual patients.

“In the field of bone substitutes there is a growing demand for customised solutions, and this technology provides a response to that challenge,” explains Simão Santos, who is enrolled in the University of Aveiro’s Doctoral Programme in Materials Science and Engineering.

The adoption of an aqueous formulation also brings relevant environmental benefits. By reducing the use of organic compounds by around 80 per cent, the process becomes more sustainable and presents a lower environmental footprint.

Further advantages are observed in the final production stage, known as sintering, which is essential to confer mechanical strength to ceramic bone substitutes. With the new formulation developed at CICECO, the duration of this step is reduced by approximately 60 per cent, leading to significant gains in energy efficiency.

The next phase of the project will focus on assessing the biological performance of the material prior to any potential clinical application. Key challenges include conducting advanced testing, meeting regulatory requirements, and demonstrating the safety and effectiveness of these innovative solutions.

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G3 - Electrochemical Materials, Interfaces and Coatings G5 - Biomimetic, Biological and Living Materials

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