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In order to merge high-mechanical properties and suitable bioactivity in a single scaffold, zirconia porous structures are here coated with a hydroxyapatite layer. The digital light processing (DLP) technique is used to fabricate two types of scaffolds: simple lattice structures, with different sizes between struts (750, 900 and 1050 µm), and more complex trabecular ones, these latter designed to better mimic the bone structure. Mechanical tests performed on samples sintered at 1400 °C provided a linear trend with a decrease in the compressive strength by increasing the porosity amount, achieving compressive strengths ranging between 128-177 MPa for lattice scaffolds and 34 MPa for trabecular ones. Scaffolds were successfully coated by dipping the sintered samples in a hydroxyapatite (HA) alcoholic suspension, after optimizing the HA solid loading at 20 wt%. After calcination at 1300 °C, the coating layer, composed of a mixture of HA and β-TCP (β-TriCalcium Phospate) adhered well to the zirconia substrate. The coated samples showed a proper bioactivity, well pronounced after 14 days of immersion into simulated body fluid (SBF), with a more homogeneous apatite layer formation into the trabecular samples compared to the lattice ones.

DLP Fabrication of Zirconia Scaffolds Coated with HA/β-TCP Layer: Role of Scaffold Architecture on Mechanical and Biological Properties