Low temperature synthesis and cold sintering of natural source derived hydroxyapatite for bone tissue engineering applications

The present thesis work is focused on the low-temperature transformation of food industry wastes like mussel shells into nanocrystalline ions-substituted hydroxyapatite powder, having similarities with natural bone apatite, on the consolidation of such powder by cold sintering, and on the physicochemical characterization of the raw materials, synthesised powders and sintered pellets. Nonetheless the evaluation of the mechanical and biological properties was carried out to address cold sintered bodies to possible scaffolds for bone tissue engineering applications. Mussel shells, like other biogenic source of calcium carbonate/phosphate, have the attractive of being a “zero”-cost raw material because they are a waste, but also of having trace elements (Mg, Na, Sr, etc.) which, if found in a bioceramic, have a positive effect on the biological properties. Therefore, mussel shell-derived hydroxyapatite could resemble the mineralized bone tissue, being natural apatite nanometric, ion substituted and with low crystalline tenor. In the first part of the manuscript, two production methods were explored: mechanochemistry and dissolution-precipitation synthesis. Mechanochemistry was carried out at room temperature by directly mixing crushed mussel shells with phosphoric acid in a ball mill. Nanocrystalline multi-ions substituted hydroxyapatite was produced after 4 h of milling and drying at 150°C. Conversely, dissolution-precipitation synthesis was carried out in two steps: the dissolution of crushed mussel shells by adding phosphoric and chloric acid occurred at room temperature, whereas the precipitation of calcium phosphates induced by soda solution, occurred at 45°C. Dissolution-precipitation was further implemented to produce a homogeneous composite material in a single-step by introducing chitosan (in a 2/5/10 wt%) during the dissolution step. The idea was to produce a composite material able to mimic the natural bone tissue composition. In the second part of the manuscript, cold sintering was investigated for the consolidation of the synthesised hydroxyapatite and hydroxyapatite-based composites at a maximum temperature of 200 °C to avoid phase transformation, limit grain growth and preserve the osteoconduction of the bioceramic materials. The effect of the main process parameters such as solvent amount, pressure, temperature and holding time was discussed. Pressure-solution creep and plastic deformation were pointed out as the fundamental consolidation mechanisms in cold sintering, the pressure playing the major role. With a synergistic combination of pressure (600 MPa), temperature (200°C) and liquid phase (20 wt%) it was possible to consolidate hydroxyapatite above 80% relative density in only 15 min. Furthermore, pressure and temperature act a complementary agent during cold sintering. In fact, it was possible to consolidate nanometric HAp and HAp/chitosan composites above 90% relative density by increasing the applied pressure up to 1.5 GPa at room temperature. The mechanical properties of cold sintered pellets were investigated, and resulted in a flexural bending strength and Vickers microhardness, respectively, of 45 MPa and 1.1 GPa for pure hydroxyapatite and of 55 MPa and 0.8 GPa for HAp/chitosan composite. In the frame of bone tissue engineering applications, cold sintered bodies were also preliminarily tested in vitro to establish their bioactivity, their cellular viability through cytotoxicity assessment, and the ability to sustain cells adhesion, osteogenic differentiation. And extracellular matrix mineralization.