Nano Materials and Structures for Superior Implants (Nanoplants)
Lead Research Organisation:
Loughborough University
Department Name: Materials
Abstract
Various RCUK funded projects at Loughborough University over the years have delivered significant foreground intellectual property and technology know-how related to the fabrication of nanostructured materials with outstanding properties, surpassing some of the commercial counterparts, relevant to the energy, electronic security and in particular healthcare sectors. Specifically it has been demonstrated that the hydrothermal ageing (HTA) resistance of zirconia based ceramics can be enhanced significantly by retaining a nano grain size below 180 nm even at low density components. This is highly relevant to the ~$5B hip replacement market where concerns about the toxicity / wear debris in metal and polymer components renders all-ceramic solutions increasingly attractive. HTA degradation (the unwanted conversion of tetragonal zirconia to a weaker monoclinic form in an aqueous environment) is the Achilles-heel for the use of zirconia ceramics in biomedical sector and was the reason behind the well-publicised failure of zirconia hip replacements around 2000. Thus, when HTA is countered, new opportunities open up. The proposed technology (involving novel nano-suspension control, granulation and then microwave assisted hybrid heating as well as flash sintering regimes; zirconia toughened alumina and zirconia ceramics will be considered) aims to deliver very small zirconia grain sizes that will both assist current compliance (e.g. ISO 13356, ISO 633-3) and open up novel all-ceramic hip replacements via multi-fold enhancement in HTA-resistance of porous and dense graded zirconia based structures. The methodology will be applicable to ceramic-metal graded implant structures also with suitable modifications. The retention of nano-size throughout all stages of ceramic component production is critical to delivering the target end properties that will assist the health and quality of life in a growing ageing population. This will be achieved via the development of implant structures (applicable for hip/knee prosthesis, finger joints and jaw & skull repairs) that deliver improved mobility over a longer time period thus reducing reliance on repeat surgery and in some cases confinement to use of wheelchair.
Planned Impact
2008 data estimates that the global hip replacement market is ~$5.6B. Knees and Spines account for a further $6.7B and 8.1B respectively and adding in trauma, extremity, sports segments create a total market of ~$31B. Between 1995 and 2008, it enjoyed a 10-15% per annum growth rate. Despite the recent economic down-turn, growth rates remain at >6%.The business opportunity addressed by this project is to create hip (and subsequently other bone) replacement components featuring a superior performance nano-ZTA or nano-zirconia and thus make in-roads firstly into the $5.6B world-wide hip replacement market and subsequently within the ~$31B world-wide orthopaedics market. Based on Hip and Knee market data, Europe has a 30 % share of the market, whilst the USA has a 50% share; it should also be noted that use of ceramics is increasing with an average 20% of implants using ceramics predicted for 2013 and above. Interestingly, Europe (up to 50% utilisation) is embracing ceramics more than the US (5% utilisation) meaning significant future export opportunities. A closer inspection of the market data also suggests that the USA, Europe and Japan account for 80% of the market, even though from a population perspective, these regions make up just 20% of the 6.7B world population. This illustrates the huge global growth potential in this area: As the standard of living in India, China, other countries rises, so will the demand for joint replacement operations.
The project partner foresees at least a doubling of their ~1M current hip markets by 2017. LU sees significant IP generation and licensing opportunities. MAM supplies components that are used in the final implant (femoral head, acetabular cup) assemblies ultimately implanted by surgeons. Companies supplying final assemblies include the following big companies (turnovers adjacent): Stryker $5.75B; J&J $4.93B; Zimmer $3.99B; S&N $2.93B. Though not part of this consortium, such companies will have a key role to play in commercialising any nano-ceramic component emerging from the project. From an environmental aspect, nano-zirconia and eco-friendly microwave and flash sintering offers the potential for lower sintering temperatures (~300-600C reduction in peak firing temperatures respectively). This will lead to significant energy savings and less CO2 emissions.
Currently 61% of joint replacements are for the 65+ age group and 36% are at 45-64, figures in both age categories are set to rise as people live longer and younger people are increasingly willing to pay for operations that allow them to enjoy sports that place a strain on joints for longer. Being able to offer patients just one hip replacement during their life can have a massive impact on quality of life and hospital costs. In 2008 there were nearly 74,000 hip replacements (50,500 NHS) in the UK. A mean stay of a week in hospital and a "cost per day in hospital" of £225 leads to £80M/year NHS cost. It can be seen that 1 instead of 2 hip replacements will bring significant benefits. The goal of achieving implant surface porosity opens up the option of having slow release anti-bacterial agents that could prevent the 2-3% rate of infections associated with hip and knee replacements annually, that further costs £5.2M to NHS. Alternatively, if impregnated with mechanically enhanced hydroxyapatite, the porous surface could provide anchorage points for live bone (see Case for Support). This could reduce the recuperation time and pressure on hospital beds.
Sale of products and a reduction in raw material consumption and recycling, or increased market share through sales of superior products that may also be more durable, will help assisting in waste minimisation. Production costs can also be lowered, raising UK competitiveness and encouraging growth in UK advanced ceramics production via development of innovative and sustainable high value products, something identified as critical in the face of low cost competition.
The project partner foresees at least a doubling of their ~1M current hip markets by 2017. LU sees significant IP generation and licensing opportunities. MAM supplies components that are used in the final implant (femoral head, acetabular cup) assemblies ultimately implanted by surgeons. Companies supplying final assemblies include the following big companies (turnovers adjacent): Stryker $5.75B; J&J $4.93B; Zimmer $3.99B; S&N $2.93B. Though not part of this consortium, such companies will have a key role to play in commercialising any nano-ceramic component emerging from the project. From an environmental aspect, nano-zirconia and eco-friendly microwave and flash sintering offers the potential for lower sintering temperatures (~300-600C reduction in peak firing temperatures respectively). This will lead to significant energy savings and less CO2 emissions.
Currently 61% of joint replacements are for the 65+ age group and 36% are at 45-64, figures in both age categories are set to rise as people live longer and younger people are increasingly willing to pay for operations that allow them to enjoy sports that place a strain on joints for longer. Being able to offer patients just one hip replacement during their life can have a massive impact on quality of life and hospital costs. In 2008 there were nearly 74,000 hip replacements (50,500 NHS) in the UK. A mean stay of a week in hospital and a "cost per day in hospital" of £225 leads to £80M/year NHS cost. It can be seen that 1 instead of 2 hip replacements will bring significant benefits. The goal of achieving implant surface porosity opens up the option of having slow release anti-bacterial agents that could prevent the 2-3% rate of infections associated with hip and knee replacements annually, that further costs £5.2M to NHS. Alternatively, if impregnated with mechanically enhanced hydroxyapatite, the porous surface could provide anchorage points for live bone (see Case for Support). This could reduce the recuperation time and pressure on hospital beds.
Sale of products and a reduction in raw material consumption and recycling, or increased market share through sales of superior products that may also be more durable, will help assisting in waste minimisation. Production costs can also be lowered, raising UK competitiveness and encouraging growth in UK advanced ceramics production via development of innovative and sustainable high value products, something identified as critical in the face of low cost competition.
Publications
Anshuman A
(2018)
Enhanced catalytic performance of reduced graphene oxide-TiO2 hybrids for efficient water treatment using microwave irradiation.
in RSC advances
Downs J
(2016)
Field Assisted Sintering of Nanostructured Zirconia-Alumina Ceramics for Demanding Applications
in Transactions of the Indian Ceramic Society
Ghanizadeh S
(2017)
Improved transparency and hardness in a-alumina ceramics fabricated by high-pressure SPS of nanopowders
in Ceramics International
Ghanizadeh S.
(2016)
Spray Freeze Granulation of Submicrometre a-Alumina Using Ultrasonication
in JOURNAL OF CERAMIC SCIENCE AND TECHNOLOGY
John A Downs
(2015)
Field assisted sintering of nanostructured ceramics for demanding applications
Ramanujam P
(2018)
Rapid synthesis of nanocrystalline YAG via microwave-assisted solvothermal process
in Journal of the American Ceramic Society
Ramanujam P
(2016)
Solvothermal nanoYAG synthesis: Mechanism and particle growth kinetics
in The Journal of Supercritical Fluids
Saremi-Yarahmadi S
(2018)
Erosion and mechanical properties of hydrothermally-resistant nanostructured zirconia components
in Ceramics International
Sumithra S
(2022)
Microwave assisted processing of X8R nanocrystalline BaTiO3 based ceramic capacitors and multilayer devices
in Open Ceramics
Wade-Zhu Y
(2021)
The ballistic impact performance of nanocrystalline zirconia-toughened alumina (nZTA) and alumina ceramics
in Journal of the European Ceramic Society
Description | The ability to produce genuinely nanostructured ceramic components suitable for healthcare, defence, electronic and energy applications using both conventional and field assisted processing methods. For the first time these components were also demonstrated to be manufactured with nanostructure, high density and significant design freedom using additive manufacturing (3D printing) methods in combination with microwave/flash sintering techniques. |
Exploitation Route | The enormous design freedom provided by the digital manufacturing techniques and the significant time and energy reduction obtained through field assisted processing methods auger well for the fabrication of engineering ceramic components (both simple and complex shaped) for a number of application sectors viz., healthcare, electronic, defence, transport etc. Through a spin-off project with one of the Nanoplants partner Morgan Advanced Ceramics - the hydrothermal testing protocols we developed have been adopted recently to perform accelerated tests to predict product lifetime of metal and ceramic reflective block sensors used in next generation ultrasonic smart flow meters - a trait that is extremely helpful to design them and reliably measure fluid flows in domestic as well as industrial situations (see press release: http://www.dpaonthenet.net/article/107091/Industry-and-Academia-go-with-the-flow.aspx ). A Plenary lecture was presented in the International Conference on Biomaterials Innovation, India , December 2020. |
Sectors | Aerospace Defence and Marine Education Electronics Energy Healthcare Manufacturing including Industrial Biotechology Security and Diplomacy Transport |
URL | https://www.researchgate.net/publication/346544643_Plenary_Lecture_on_Additive_Manufacturing_of_Nanostructured_Bioceramic_Implants_International_Conference_on_Biomedical_Materials_Innovation_December_2020 |
Description | For the first time nanostructured zirconia and ZTA based ceramic components, femoral heads, acetabular cups, dental implants were manufactured using additive manufacturing and field assisted sintering techniques. This has opened up a huge potential for personalised healthcare options as well as highly complex shaped ceramics production with significant design freedom. This can be applied further to the development of highly efficient energy materials, electronic ceramics, armour systems as well as functionally gradient materials for demanding applications. Recently BBC4 invited LU's advanced ceramics group to feature in a Documentary (Oct 2018) on "The Secret Story of Stuff: Materials of the Modern Age" . This programme explored the world of material science, uncovering the innovations in manufacturing that are set to change the world we live in. The Consul General of India Visited Loughborough University on 15th February 2022 to help forge research, teaching and enterprise links with India. He visited the School of AACME and our world leading research and innovation labs on Advanced Ceramics and 3D printing along with Power Trains, EV/Unmanned Vehicles, LMCC, Caterpillar IRC, LMCC etc. |
First Year Of Impact | 2022 |
Sector | Aerospace, Defence and Marine,Digital/Communication/Information Technologies (including Software),Education,Electronics,Energy,Environment,Healthcare,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology,Transport |
Impact Types | Cultural Societal Economic Policy & public services |
Description | Grand Challenge |
Amount | £4,000,000 (GBP) |
Funding ID | EP/N010493/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 03/2016 |
End | 02/2021 |
Description | Knowledge Transfer Partnership |
Amount | £232,234 (GBP) |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 06/2017 |
End | 06/2020 |
Description | Rapid manufacture of solid-state battery structures by additive manufacturing and Flash sintering |
Amount | £240,264 (GBP) |
Funding ID | 10007480 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 06/2021 |
End | 07/2022 |
Description | Invited member of the advisory mentoring committee |
Organisation | Indian Institute of Science Bangalore |
Country | India |
Sector | Academic/University |
PI Contribution | PI has been invited to be a member of the advisory committee for their Translational Centre of Excellence in Biomaterials |
Collaborator Contribution | They are also working in the area of ceramics and composites for biomedical applications and are keen for us to take part in the discussions, mentoring and guidance to achieve the CoE's vision. |
Impact | Not yet. |
Start Year | 2016 |
Description | Invited to Ivoclar Vivadent Company to discuss possible collaboration |
Organisation | Ivoclar Vivadent AG |
Country | Liechtenstein |
Sector | Private |
PI Contribution | The work developed under Nanoplants grant was responsible for this industrial invitation. The pioneering research conducted on 3D printing and flash sintering of bioceramic components at Loughborough by the team was instrumental for this collaboration. |
Collaborator Contribution | They contacted us for initiating the collaboration based on our reputation in this area. |
Impact | A meeting is planned to discuss possible future collaboration activities. |
Start Year | 2017 |
Title | DEFORMABLE GRANULE PRODUCTION |
Description | A method of forming granules, the method including forming a suspension of a nanopowder such as a nano zirconia powder containing yttria. The powder is formed from a suspension, and freon is added directly to the suspension as an additive. The suspension is then granulated by spray freeze drying, and the freon subsequently removed by heat treatment. The voids left by the vacated freon provide meso, micro and macro flaws or structural defects in the granules. |
IP Reference | US2011241236 |
Protection | Patent application published |
Year Protection Granted | 2011 |
Licensed | No |
Impact | This discovery that was originally developed for zirconia ceramics is successfully employed for a number of nanoceramic systems such as YAG, Alumina, Zirconia Toughened Alumina etc. |
Title | DEFORMABLE GRANULE PRODUCTION |
Description | This is an EU patent related to the Spary Freeze Drying of flowable and crushable nanoceramic granules for producing engineering components. |
IP Reference | EP2346951 |
Protection | Patent application published |
Year Protection Granted | 2011 |
Licensed | Commercial In Confidence |
Impact | It has opened up a new collaborative opportunity with world leading dental component company in Liechtenstein. This is because this patent has covered that part of the globe also and got noticed. |
Title | DOPED ZIRCONIA CERAMIC |
Description | The present invention provides the use of a doped zirconia ceramic having a mean grain size of about 190 nm or less and consisting of the tetragonal zirconia crystallographic phase as a hydrothermally stable material or in an application that requires the use of a hydrothermally stable material. The present invention also provides a doped zirconia ceramic having a mean grain size of about 190 nm or less and consisting of tetragonal zirconia which does not undergo detectable tetragonal to monocli |
IP Reference | EP2364282 |
Protection | Patent application published |
Year Protection Granted | 2011 |
Licensed | No |
Impact | This has open up a huge interest in the nanostructed zirconia and other ceramics developed at Loughborough University and many companies have shown keen interest to engage with the Advanced Ceramics group for project colloboration in their respective fields such as defence, electronics, energy and healthcare sectors. |
Description | BBC4 documentary on our nanostructured implants work |
Form Of Engagement Activity | A broadcast e.g. TV/radio/film/podcast (other than news/press) |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Media (as a channel to the public) |
Results and Impact | Our research work on 3D printing of nanostructured ceramics for healthcare applications had featured in a hour long BBC 4 documentary titled "The Secret Story of Stuff: Materials of the Modern Age." It explores the world of material science, uncovering the innovations in manufacturing that are set to change the world we live in. See: https://www.lboro.ac.uk/departments/materials/news/2018/materials-at-loughborough-featured-in-bbc-4-documentary.html This was also reviewed as one of the best TV educational programmes by many newspapers of the country including Guardian. https://www.theguardian.com/tv-and-radio/2018/oct/31/secret-story-stuff-tv-review |
Year(s) Of Engagement Activity | 2018 |
URL | https://www.lboro.ac.uk/departments/materials/news/2018/materials-at-loughborough-featured-in-bbc-4-... |
Description | Ceramics expo - press release |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | Through a spin-off project from Nanoplants our collaborating partner Morgan Advanced Materials has developed the capability to produce complex ceramic acoustic reflectors used in ultrasonic flow meters, drawing on pioneering research carried out in conjunction with Loughborough University (UK), ensuring consistent measurement accuracy over a longer projected lifespan. |
Year(s) Of Engagement Activity | 2017 |
URL | http://www.ceramicsexpousa.com/resources/news/2016/12/14/morgan-announces-ceramic-acoustic-reflector... |
Description | Gave an invited inaugural talk titled " Materials and Manufacturing Innovations for a Sustainable Future" at the workshop on "Two-dimensional Nanomaterials for Medical and Environmental Applications (2D-NaMEA)" on 26th February 2024 organized by Center for Materials Informatics, Anna University, Chennai. |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Postgraduate students |
Results and Impact | More than 101 participants attended the workshop and Prof. Balasubramaniam Vaidhyanathan was invited to give the Inaugural address at the meeting organised by the Centre for Material Informatics from Anna University (AU), Chennai, India. There was a very engaging and thought provoking QA session and discussion followed with the staff and students of the university. There was a also discussion held about initiating a new Master's programme between Anna University, India and Loughborough University, UK on Advanced Materials Science and Engineering including with the Vice Chancellor of the AU. |
Year(s) Of Engagement Activity | 2024 |
URL | https://www.annauniv.edu/C-mAIn/events.html |
Description | International Keynote Talk |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | Invited Keynote Presentation |
Year(s) Of Engagement Activity | 2022 |
URL | https://magnusconferences.com/materials-science/speaker/bala-vaidhyanathan |
Description | Interview to Technopolis Limited |
Form Of Engagement Activity | Engagement focused website, blog or social media channel |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Third sector organisations |
Results and Impact | An interview was given to Technopolis Limited on the outcomes of the Nanoplants HIP project funded by EPSRC. This will form part of the case study document. |
Year(s) Of Engagement Activity | 2020 |
Description | Invited Talk |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | International Conference on Powder Metallurgy & Particulate Materials + Exhibition 2023 (PMAI-PM 23). Delivered an Invited talk on "3D printing of Advanced Ceramics". 50 people attended the session, the talk well received with many students and researchers asking informed questions at the end. Could open up an international collaborative opportunity with the Collage of Engineering Pune (CEOP), India. |
Year(s) Of Engagement Activity | 2023 |
URL | https://pmai.in/PM-23/important-date.html |
Description | Invited presentation in a prestigeous international congress |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | Gave an invited presentation in the 7th International Congress on Ceramics held at Brazil (2018). This is a very important conference for the advanced ceramic materials practitioners and it was excellent to represent our pioneering work on 3D printing of ceramics and green processing. This has resulted in an invitation to write a book with one of the most famous book publishers. |
Year(s) Of Engagement Activity | 2018 |
URL | http://www.icc7.com.br/ |
Description | Keynote Presentation |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Postgraduate students |
Results and Impact | Keynote Presentation made at the 4th Edition of International Conference on Materials Science And Engineering - Materials 2023. More than 60 people attended and the talk was well received and good discussion ensued. Also involved in the scientific organising committee of this conference. |
Year(s) Of Engagement Activity | 2023 |
URL | https://magnusconferences.com/materials-science/program/scientific-program/2023/2d-3d-manufacture-of... |
Description | Keynote Presentation |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | Presented a keynote lecture at the International Conference on Biomaterials, BioEngineering & BioTheranostics (BioMET 2018), In Vellore, India. The talk was extremely well received and our institution was invited to take part in further collaborative initiatives and a mutual exchange visits have taken place. |
Year(s) Of Engagement Activity | 2018 |
Description | Plenary Lecture |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Postgraduate students |
Results and Impact | Prestigious Plenary lecture presented at the International Conference on Biomaterials Innovation, India on December 2020 to wider audience with mix of research students, academic and industry people, healthcare professionals etc |
Year(s) Of Engagement Activity | 2020 |
Description | Plenary talk at 17th International AMPERE Conference, Spain |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | A Plenary talk in 17th International Conference on Microwave and High Frequency Heating (APERE 17), at Valancia, Spain in September 2019. The talk was extremely well received and the PI received invites to present the findings in other conferences and new discussion on future collaboration ensued. One of the researcher attended has made a successful internship application to come and work in UK from Spain. |
Year(s) Of Engagement Activity | 2019 |
URL | http://ampere2019.com/plenary-keynotes-speakers/ |
Description | Press Release and Ceramics Expo |
Form Of Engagement Activity | A press release, press conference or response to a media enquiry/interview |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | Through a spin-off project with one of the Nanoplants partner Morgan Advanced Ceramics - the hydrothermal testing protocols we developed have been adopted recently to perform accelerated tests to predict product lifetime of metal and ceramic reflective block sensors used in next generation ultrasonic smart flow meters - a trait that is extremely helpful to design them and reliably measure fluid flows in domestic as well as industrial situations (see press release: http://www.dpaonthenet.net/article/107091/Industry-and-Academia-go-with-the-flow.aspx ). This developed product also planned for showcase at Ceramics Expo 2017 in USA (see: http://www.ceramicsexpousa.com/resources/news/2016/12/14/morgan-announces-ceramic-acoustic-reflector-manufacturing-capability-for-flow-metering/ ). |
Year(s) Of Engagement Activity | 2015,2016 |
URL | http://www.dpaonthenet.net/article/107091/Industry-and-Academia-go-with-the-flow.aspx |
Description | Prof. B. Vaidhyanathan gave an invited talk titled "Education - a New Perspective" to UG and PG students (and their parents) at the Pollachi Institute of Engineering and Technology, India during his recent trip in Feb 2024. This was attended by more than 300 students. |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Undergraduate students |
Results and Impact | Prof. B. Vaidhyanathan gave an invited talk titled "Education - a New Perspective" to UG and PG students (and their parents) at the Pollachi Institute of Engineering and Technology, India during his recent trip in Feb 2024. This was attended by more than 300 students. After the talk there was a very lively QA session and discussion on opportunities for students studying high education abroad and that lasted for more than an hour! Many students were keen on taking up the opportunities and showed significant enthusiasm with the information shared. |
Year(s) Of Engagement Activity | 2024 |
Description | Visit by the Consul General of India to the Advanced Ceramics and 3D Printing labs in the School of AACME |
Form Of Engagement Activity | A press release, press conference or response to a media enquiry/interview |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Policymakers/politicians |
Results and Impact | The Consul General of India Visited Loughborough University on 15th February 2022 to help forge research, teaching and enterprise links with India. He visited the School of AACME and our world leading research and innovation labs on Advanced Ceramics, 3D printing, Power Trains, EV/Unmanned Vehicles, LMCC, Caterpillar IRC etc. |
Year(s) Of Engagement Activity | 2022 |
URL | https://www.lboro.ac.uk/internal/news/2022/february/visit-by-consul-general-of-india/ |