Development of highly open polyhedral networks from vitreous carbon for orthopaedic applications

Highly open polyhedral networks were fabricated using an economical and environmentally friendly template route. Recycled cellulose foams were impregnated with a sucrose resin and then pyrolyzed in order to produce reticulated vitreous carbon foams with morphological features that closely resemble trabecular bone. Also, cell sizes ∼1mm were achieved, a trait that will allow the mechanical reinforcement of such scaffolds using a biomaterial coating without compromising the pore size that favors osteoblast cell infiltration and growth (200-500μm). Moreover, initial studies showed that carbonization conditions have an effect on the mechanical properties of the synthesized foams and, therefore, such process parameters could be further evaluated towards the enhancement of the mechanical resistance of the scaffolds. The materials developed here are visualized as the porous component of a synthetic bone graft with features that could help overcome the current limitations associated with the medical treatments used for bone defect repair.