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Biosilicate® glass-ceramics are among the most valid alternatives to 45S5 Bioglass. They combine a similar bioactivity and bioresorbability as the 45S5 with superior mechanical strength, owing to the crystallization of a Na–Ca silicate phase. This crystallization may be experienced upon viscous flow sintering of fine glass powders, thus configuring a sinter-crystallization process. As crystallization is seldom complete, sintering can also be applied to semicrystalline powders. The sintering/crystallization combination may be exploited for shaping highly porous bodies, to be used as scaffolds for bone tissue engineering, in the form of foams. The present study aims at exploring a gel-casting process, based on the room temperature foaming of powders suspended in a “weakly alkaline” (1 M NaOH) aqueous solution, followed by sintering at 1,000°C. The gelation of suspensions is attributed to the formation of hydrated compounds, later decomposed upon firing. Amorphous powders provided more intense gelation than semicrystalline ones, promoted a more homogeneous foaming, and stimulated a substantial crystallization upon firing. The homogeneity of foamed samples was assessed using micro-tomography and was further improved by casting foamed suspensions (“foam casting”) before setting.

Biosilicate® Glass-Ceramic Foams From Refined Alkali Activation and Gel Casting