Fabrication of a polymeric prosthetic implant

A construct made by the following process:

• (a) providing a solution comprising chains of a primary photocurable, bioerodable polymer, a primary photoinitiator for promoting photocrosslinking of the chains of the primary polymer, and a solvent, wherein the primary polymer is poly(propylene fumarate)(PPF);
• (b) providing a stereolithography instrument comprising a primary UV laser for activating the primary photoinitiator and photocrosslinking the PPF chains;
• (c) providing a three dimensional CAD image of a desired three-dimensional prosthetic implant, wherein the three-dimensional CAD image is readable by the stereolithography instrument;
• (d) depositing the solution in successive layers on a build platen in the stereolithography instrument;
• and
• (e) photocrosslinking at least a portion of the PPF chains in each of the successive layers according to corresponding cross-sectional patterns derived from the three dimensional CAD image
• wherein the construct has a shape and size corresponding to the desired three dimensional prosthetic implant,
• wherein the construct comprises solid regions comprising photocrosslinked PPF chains;
• and
• wherein the construct has a network of interconnecting pores and channels corresponding to a network of interconnecting pores and channels designed into the three CAD image, wherein one or more of the channels extend from a location inside the construct to a predetermined location on the exterior surface of the construct, and wherein the one or more channels are for promoting migration of vascular and bone progenitor cells into the interior of the construct.

A composite polymeric construct made by a process comprising the steps of:

• (a) providing a solution comprising chains of a primary photocurable, bioerodable polymer and a secondary photocurable polymer, a primary photoinitiator for promoting photocrosslinking of the chains of the primary polymer, a secondary photoinitiator for promoting photocrosslinking of the chains of the secondary polymer, and a solvent, wherein the primary polymer is poly(propylene fumarate)(PPF);
• (b) providing a stereolithography instrument comprising a primary UV laser for activating the primary photoinitiator and photocrosslinking the PPF chains, and a secondary UV laser for activating the secondary photoinitiator and photocrosslinking chains of the secondary polymer;
• (c) providing a three dimensional CAD image of a desired three-dimensional prosthetic implant, wherein the three-dimensional CAD image is readable by the stereolithography instrument;
• (d) depositing the solution in successive layers on a build platen in the stereolithography instrument;
• and
• (e) photocrosslinking PPF chains and chains of the secondary polymer in each of the successive layers according to corresponding cross-sectional patterns derived from the three dimensional CAD image;
• wherein the composite polymeric construct has a shape and size corresponding to the three-dimensional CAD image,
• wherein the composite polymeric construct comprises solid regions comprising photocrosslinked PPF chains;
• wherein the composite polymeric construct comprises solid regions comprising photocrosslinked chains of the secondary polymer;
• and
• wherein the prosthetic implant has a network of interconnecting pores and channels leading from the exterior surface to an interior location in the prosthetic implant.