Vat photopolymerization of ultra-porous bioactive glass foams

The introduction of additive manufacturing technologies in the field of biomaterials science has opened new horizons for regenerative medicine. In this work, we pushed the potential of vat polymerization to the limit for fabricating ultra-porous bioactive SiO 2 -CaO-MgO-P 2 O 5 -CaF 2 -Na 2 O glass scaffolds with bone-like architectural characteristics. The tomographic reconstruction of an open-cell foam was used as input file to the printing system and reliably reproduced in all its exquisite details, as assessed by morphological analyses of sintered scaffolds (thickness of single struts 35 μm, exceptionally high porosity around 94 vol%, most pores with size from 500 to 900 μm). Immersion studies in simulated body fluid (SBF) revealed the apatite-forming ability (i.e., in vitro bioactivity) of the scaffolds, the surface of which started being coated by calcium phosphate after just 3 days from the beginning of the experiments. Taken together, these results show great promise for application of such scaffolds in bone defect repair. • Vat photopolymerization was used to fabricate exceptionally-porous (>94 %) glass scaffolds. • The CT reconstruction of a polymer foam was used as input CAD file to the printer. • The foam architecture was replicated in the additively-manufactured glass scaffolds. • Scaffolds exhibit apatite-forming ability (bioactivity) in vitro.