In Situ Hydrogel Growth on Flame-Sprayed Hydroxyapatite (HA)/TiO2-Coated Stainless Steel via TiO2-Photoinitiated Polymerization

Hydroxyapatite (HA) coatings improve implant bioactivity but suffer from brittleness and limited functionality. Here, we report a hybrid coating strategy combining flame-sprayed HA/TiO₂ with in situ hydrogel growth. TiO₂ incorporated into the HA matrix acted as a photocatalytic initiator for acrylamide polymerization under UV. Unlike conventional hydrogel coatings that require added photoinitiators or separate surface modification steps, TiO₂ incorporated into the HA layer serves as a built-in photocatalytic initiator, enabling direct polymerization of acrylamide monomers on the sprayed surface. The resulting HA/TiO₂-hydrogel coatings exhibited a continuous hydrogel layer with intimate contact to the ceramic surface, as evidenced by SEM cross-sections and elemental mapping. The HA/TiO₂ 1% coating produced a continuous coverage in close contact with the surface, while excessive TiO₂(5%) led to uncontrolled hydrogel growth and partial coating failure. SEM cross-sections revealed a dense, well-adhered coating with homogeneously distributed Ca, P, O, and finely dispersed Ti. Upon immersion in simulated body fluid (SBF), submicron globular deposits progressively developed on the coating surface. EDS showed an increase in Ca/P ratio from ~1.66 (as-sprayed) to ~1.92 (14 days). These findings highlight a straightforward approach for combining flame-sprayed ceramics with photocatalytic hydrogel growth, providing a practical route toward multifunctional implant surface modification.