Tissue regeneration matrices by solid free-form fabrication techniques

A medical device for bone regeneration formed using three dimensional printing comprising a matrix of successive layers of biocompatible composite material having interconnected pores extending throughout the matrix suitable for seeding or ingrowth of cells, having a pore size of at least five to forty microns in diameter

• wherein the method comprises
• a) spreading a first dispersion of a resorbable powder selected from the group consisting of calcium phosphate, hydroxyapatite, and calcium carbonate onto a bed,
• b) printing a layer comprising a second dispersion of biocompatible polymer or composite powder in a solvent which binds the first powder to the second biocompatible polymer or composite powder at locations where it is desired to have walls, and
• c) repeating steps a and b until the desired matrix is made.

A rectangular device for bone regeneration of approximate size 2 cm×1 cm×1 cm, comprising:

• a) a first layer comprising:
• (i) lines approximately 100 microns wide spaced approximately 300 microns center-to-center along the length of the 2 cm axis, wherein each line is 200 microns in depth, totaling 30 lines, and
• (ii) triplets of approximately 100 micron wide lines with approximate 100 micron spacing in between printed along the 1-cm axis, for a total of 25 triplets;
• b) a second layer comprising lines approximately 100 microns Wide spaced approximately 300 microns center-to-center along the length of the 2-cm axis, wherein the lines are approximately 200 microns in depth and placed directly above the lines in the first layer;
• c) a third layer comprising lines approximately 100 microns wide with approximate 100 micron spacing printed along the 1 cm axis with approximate 100 micron spacing in between with an approximate 200 micron depth, and wherein the lines are printed on top of each of the outside lines in each triplet in the layer below;
• d) a second-to-last layer that is the same as the second layer;
• e) a layer between the second-to-last layer and the last layer that is the same as the third layer;
• and
• f) a last layer that is the same as the first layer.