Additive Manufacturing of Crack-Free, Ductile Zirconia-Based Composite for Medical Implants

Objective

Reconstruction of craniomaxillofacial and oral hard tissues is crucial for restoring function and quality of life (QoL) in patients with extensive bone defects or edentulism. However, the growing demand for personalised, metal-free implants is hindered by several critical limitations, including the inherent brittleness of ceramic materials, limited customisation, and low manufacturing reliability due to processing-related defects. AMICERA addresses these challenges by developing reliable, patient-specific dental implants from novel ductile ceramic composites (Ce-TZP–Al2O₃–SrAl₁2O₁₉) using stereolithography-based additive manufacturing (AM), combined with a non-destructive defect detection strategy via X-ray computed tomography (XCT) enhanced by artificial intelligence (AI). The project will generate fundamental insights into the AM processing–structure–property relationships of this ductile ceramic material, enable its transformation into complex implants tailored to individual anatomies and ensure implants' reliability through AI-powered defect analysis. By pioneering a transformative, metal-free approach for personalised reconstructive therapies, AMICERA will address urgent public health needs linked to Europe’s ageing population. Ultimately, this project will expand treatment options for patients currently excluded from conventional implant therapy or who are unable or unwilling to receive metal-based solutions, thus enhancing QoL, broadening access to care, and potentially transforming modern implantology.