Bioceramics & Coating

We strongly believe in collaborative research and through effective alliance programs, that include close association of scientists, technologists, surgeons and industries, we actively work on research project that translate into effective healthcare products. With this ideology our research group has developed ceramic femoral head articulating against standard polyethylene of hip joint prosthesis. This product has been clinically tested followed by commercialization. Currently, we are working on new ceramic matrix composite for ceramic-on-ceramic articulating system for Total Hip Arthroplasty. To improve osseointegration of metallic implants we have developed bioactive hydroxyapatite (HAp) coating using plasma spraying and these coatings have been tested clinically. Other commercial biomedical products developed by the division include bioglass coatings, bioactive ceramic scaffolds with controlled porosity characteristics, calcium phosphate granules (single and biphasic) for dental and orthopaedic applications and hydroxyapatite based integrated orbital implant. Other important materials for biomedical applications that are currently under development include ceramic composites, hard coatings, bioglass and nanopowder for drug delivery. In addition to healthcare section, our division is developing ceramic components such as high-temperature, non-shrinkable ceramic potting material, freestanding diamond windows and diamond rods for supports in helix traveling-wave tube (TWT), as a part of India’s contribution towards International Thermonuclear Experimental Reactor (ITER) program.

The division has developed 11 technologies, commercialized 9 technologies and received two best technology awards from Government of India. We currently hold 23 patents including 2 USA and Japan patents. Currently, the division has research funding of ₹ 489 million (USD 7.69 million) during 2012 – 2018 and the divisional members include 7 scientists, 8 technical staff, 17 students (10 Ph.D.; 2 M.Tech; 5 Project staff).

Due to our extensive collaboration throughout the country and abroad, our research activities include:

1. Orthopaedic, dental and maxillofacial implants/materials
   1. Ceramics and ceramic composites for hip and knee prosthesis.
   2. Metallic and ceramic implants for finger joints, oncology and spine replacement.
   3. Bioresorbable materials for bone replacement.
   4. Bioactive glass and ceramic based cements/materials.
2. Tissue engineering & drug delivery
   1. Bioactive, porous materials for orbital implants and wound dressing applications.
   2. Tailored/designed scaffolds for onsite drug delivery.
   3. Nanoceramic based inorganic drug delivery systems for cancer therapy.
3. Reconstructive and Trauma materials
   1. Tailored/designed scaffolds for orthopaedic, cosmetic, cranioplasty reconstruction.
   2. Patient specific and customized implants via additive manufacturing.
4. Coatings
   1. Hard, wear resistance and biocompatible metallic, ceramic and composite coatings for load-bearing implants.
   2. Bioactive, osteoconductive and osteoinductive coatings on bioinert medical materials.
   3. Porous coatings for bone tissue ingrowth.
   4. Microwave plasma chemical vapor deposition of diamond coatings.
5. Other materials and areas
   1. Ceramic and polycrystalline diamond materials for electron tubes.
   2. Ceramic joining.
   3. Microwave processing of ceramic materials.
   4. Unconventional cancer and wound treatment.

Collaboration
India

• Indian Institute of Technology, Madras.
• Indian Institute of Technology, Kanpur.
• Indian Institute of Technology, Delhi.
• Indian Institute of Science, Bangalore.
• Indian Institute of Technology, Kharagpur.
• Vellore Institute of Technology, Vellore.
• National Institute of Technology, Suratkal.
• Malaviya National Institute of Technology, Jaipur.
• West Bengal U of Animal & Fishery Sci, Kolkata.
• Sancheti Inst. for Orthop. & Rehabilitation, Pune.
• Tata Memorial Hospital, Mumbai.
• Jubilant Kalpataru Hospital, Barasat.
• Disha Eye Hospitals and Research Centre (P) Ltd., Barrackpore, West Bengal.
• Sri Sankaradeva Nethralaya, Guwahati.
• Saijyothi Eye Institute, Secunderabad.
• Sir Ganga Ram Hospital, New Delhi.
• Wockhardt Medical Centre, Kolkata.
• R.G. Kar Medical College & Hospital, Kolkata.
• Burdwan Medical College & Hospital, Burdwan.
• Calcutta Medical College & Hospital, Kolkata.
• Regional Institute of Ophthalmology, National Medical College and Hospital, Kolkata.
• N.R.S. Medical College and Hospital, Kolkata.
• Sambhu Nath Pandit Hospital, Kolkata.
• Calcutta Medical Research Institute, Kolkata.
• All India Institute of Medical Sciences, New Delhi.
• Maulana Azad Dental College & Hospital, New Delhi.
• Dr. Rafi Ahmed Dental College & Hospital, Kolkata.
• M/s General Surgical Company (India) Pvt Ltd., Chennai.
• M/s Orthotech, Gujarat.
• M/s Mu Biomagg, Gujarat.

Foreign

• Medical University of Vienna, Austria.
• Washington State University, USA.
• University of Louisville, USA.
• A.M. Prokhorov Gen. Phys. Inst., Russia.
• University of Aveiro, Portugal.
• University of Turku, Finland.
• Abo Academy University, Finland.
• Univ. of Vigo, Spain.
• Mindanao State Univ., Philippines.
• Universität Bremen, Germany.

Technologies available for licensing

1. Ceramic based total hip prosthesis (ceramic-on-PE).		2.Plasma spray hydroxyapatite coating on metallic biomedical implants.
3. Manufacture of bioactive ceramic scaffolds with controlled porosity characteristics.		4. Calcium phosphate granules (single and biphasic) for dental and orthopaedic applications.
5. Hydroxyapatite based integrated orbital implant.		6. High-temperature protective coatings for automobile heater plugs.
7. Glass lining coatings.		8. High-temperature protective coatings.
9. Bioactive glass coatings for orthopaedic and dental applications.		10. Plasma spray grade hydroxyapatite powder preparation.
11. Injectable, biodegradable bone cement composite with/without drugs.

Technologies under development

Technology Readiness Index: Idea, Concept Definition, Proof of Concept, Prototype, Lab Validation, Technology Development, Technology Demonstration, Technology Integrated, Market Launch.

Completed Projects

Collaboration
India

• Indian Institute of Technology, Madras.
• Indian Institute of Technology, Kanpur.
• Indian Institute of Technology, Delhi.
• Indian Institute of Science, Bangalore.
• Indian Institute of Technology, Kharagpur.
• Vellore Institute of Technology, Vellore.
• National Institute of Technology, Suratkal.
• Malaviya National Institute of Technology, Jaipur.
• West Bengal U of Animal & Fishery Sci, Kolkata.
• Sancheti Inst. for Orthop. & Rehabilitation, Pune.
• Tata Memorial Hospital, Mumbai.
• Jubilant Kalpataru Hospital, Barasat.
• Disha Eye Hospitals and Research Centre (P) Ltd., Barrackpore, West Bengal.
• Sri Sankaradeva Nethralaya, Guwahati.
• Saijyothi Eye Institute, Secunderabad.
• Sir Ganga Ram Hospital, New Delhi.
• Wockhardt Medical Centre, Kolkata.
• R.G. Kar Medical College & Hospital, Kolkata.
• Burdwan Medical College & Hospital, Burdwan.
• Calcutta Medical College & Hospital, Kolkata.
• Regional Institute of Ophthalmology, National Medical College and Hospital, Kolkata.
• N.R.S. Medical College and Hospital, Kolkata.
• Sambhu Nath Pandit Hospital, Kolkata.
• Calcutta Medical Research Institute, Kolkata.
• All India Institute of Medical Sciences, New Delhi.
• Maulana Azad Dental College & Hospital, New Delhi.
• Dr. Rafi Ahmed Dental College & Hospital, Kolkata.
• M/s General Surgical Company (India) Pvt Ltd., Chennai.
• M/s Orthotech, Gujarat.
• M/s Mu Biomagg, Gujarat.

Foreign

• Medical University of Vienna, Austria.
• Washington State University, USA.
• University of Louisville, USA.
• A.M. Prokhorov Gen. Phys. Inst. , Russia.
• University of Aveiro, Portugal.
• University of Turku, Finland.
• Abo Academy University, Finland.
• Univ. of Vigo, Spain.
• Mindanao State Univ., Philippines.
• Universität Bremen, Germany.

Laser based additive manufacturing facility (MR-7, Optomec Inc., USA)
Laser Engineered Net Shaping (LENS^TM) is an laser based additive manufacturing facility that uses metal powder to create net shape functional parts from CAD files for variety of applications. Our system uses 500W fiber laser with 0.5 mm beam diameter. The process begins with creating a molten metal pool on a substrate fixed to a X-Y CNC table. A predetermined amount of powder is fed into the liquid metal pool and as the substrate moves a thin line of metal strongly bonded to substrate will be created. A cross section is built by overlapping these thin lines. The deposition head moves up once the layer is deposited and process is repeated until the part represented in CAD file is fabricated. Parts with fully dense or tailored internal architecture or porosity can be built. We have successfully processed Ti, Ti6Al4V, stainless steels, NiTi alloy, intermetallics, and metal matrix composites.

Air plasma spraying facility (9M, Sulzer Metco.)
Our 80 kW air plasma spray system consists of plasma spray gun, spray controlling unit, power supply unit, distribution unit, powder feeder unit, etc. The unit can deposit variety of materials creating sound coatings of different substrates for biomedical and other engineering applications. We have successfully deposited hydroxyapatite, tri-calcium phosphate and/or bioactive glass coatings on metallic biomedical implants/ devices with different designs. Other types of coatings such as in-situ metal matrix coatings and porous metal coatings are currently under development for bone implant applications.

Microwave plasma chemical vapor deposition system (DT1800, Lambda Technologies Inc. USA)

One MPCVD reactor with 915 MHz and 15 kW microwave generator has been installed as a part of 11th five year plan period. We have extensively used this system for growing free standing diamond for microwave application, which is a part of ITR project. We have successfully demonstrated fabrication capability up to 60 mm diameter and 0.6 – 0.8 mm thick polycrystalline diamond discs for this application.

Chemo-mechanical (CMP) polishing (CETR, USA)

This apparatus has been specifically customized to polish hard materials such as CVD diamond developed in our laboratory. The instrument has capability to polish at varying process parameters such as normal load, sliding speed, travel speed and has provision to dispense specified amount of polishing fluids to control rate of polishing.
Using this process we could reduce the surface roughness of CVD diamond from ~ 6 µm to 200 nm.
Hot and cold isostatic presses (QIH-6, Avure Technologies Inc., USA; EPSI, Belgium)
Both these presses are primarily used to compact ceramic materials. The cold isostatic press is primarily used to achieve high green density of ceramic materials using pressures up to 400 MPa. On the other hand, the hot isostatic press is being used to combine pressing and sintering in one step. Further, we use this process to achieve highest possible sintered density in ceramics for demanding applications such as medical applications. The hot isostatic pressing capabilities include up 2000?C temperature and 200 MPa pressure.

Hip and knee joint simulators (8511, Instron, USA; ProSIM, Simsol Ltd., UK)
In vitro tribological testing using implant simulators is an important aspect in pre-clinical validation of articulating biomaterials as these tests simulate in vivo physiological conditions (loading and movements) thereby providing close in vivo wear performance of articulating biomaterials. It was observed that the wear particles retrieved from sliding wear testing were considerably larger (100-500 nm) than those obtained from hip simulator testing (5-70 nm) and the discrepancy is primarily due to the differences in wear test conditions such as sample geometry, type of loading, sliding, etc. Since the periprosthetic tissue reactions and osteolysis surrounding the hip and the knee implants are linked to the total wear particle characteristics such as volume, particle size, shape and composition tribological testing using joint simulators assumes significant importance. Therefore, we perform tribological evaluations of our materials and designs using these implant simulators to validate their performance.

Gamma-ray sterilization facility (GC 5000, BRIT, BARC)

This facility is being used for sterilization of implants for clinical trials and also to study the effect of gamma ray on the physical and mechanical properties of the new materials that are being developed at our division. Our facility has a Co60 source which works both at low and high doses, e.g., 10 kGy for food processing; 25 kGy for regular disinfection of metal/ ceramic/ polymer implants.

In vitro tissue culture laboratory
This laboratory is equipped with the following:
Class II Type A2 Biosafety Cabinet (ESCO):

Our biological safety cabinet is latest generation of energy efficient biosafety cabinet and utilizes ULPA filters for contamination protection. The exterior is coated with Isocide™ powder coating to prevent microbial/bacterial growth. All types of our in vitro cell culture experiments will be performed in this biosafety cabinet.

CO2 incubator: This incubator is being used in our research to grow and maintain cell cultures. Our fields of application include tissue engineering, in vitro culturing, cancer research, and other cell research.

Tissue culture inverted microscope: This inverted microscope is used for biological applications such as to view tissue culture specimens grown in flask.

Plate reader: The reader is used to detect biological, chemical or physical activities of cells. We use 96-well plate with a typical media volume of 100-200 µL/well. The absorbance is detected for quantitative assays such as protein/enzyme activity assays (MTT assay for cell viability). The amount of transmitted light is related to the concentration of desired molecule.

Gel documentation unit: The gel doc imager is an automated and time-saving system to image and analyze electrophoresis gels. The data can be viewed, modified and reported using the Image Lab software. This technique identify and image cellular protein/nucleic acids in a given state, e.g., by application of a new formulation/therapeutic agent etc.

In vitro tribological and electrochemical testing facilities (Nanovea, USA; Bio-Logic Science Instruments SAS, France)

Our tribological testing system is equipped with rotating and pseudo linear reciprocating type wear testing modules. The test setup also contains accessories to carry out tests in physiological fluid with precise temperature control to represent biological environment in the body. Ball-on-disc or pin-on-disc wear testing can be performed using tribometer with ? 3 mm or ? 6 mm pins rubbing against test samples. Normal loads up to 40N can be used for tests.

Electrochemical testing setup has potentiostat, galvanostat, electrometer and frequency response analyzer (FRA) designed to perform several electrochemical research experiments. We extensively use this instrument for electrochemical performance evaluation, such potentiodynamic, electrochemical impedance analysis, of variety of materials and coatings we develop for biomedical applications.

Optical microscope with fluorescence attachment (Olympus, Japan)

This microscope has Bright Field (BF), Differential Interference Contrast (DIC) and Reflected Fluorescence observation facilities with Image Analysis capabilities. The microscope is capable to perform microstructural investigation/imaging for different materials as well as biological samples with Fluorescence attachment.

Compact scanning electron microscope with composition analysis (EDX) (Phenom proX, Phenom-World B.V., Netherlands)

This is compact/desktop SEM with BSE detector with composition analysis capability (point, line scan and mapping) using EDX detector. The magnification can go up to 40,000X. We have three types of samples holder to image microstructures and composition analysis of conductive, non-conductive and mounted samples.

General facilities

• Hydraulic and mechanical presses of different capacities.
• Ceramic implants/samples machining facility.
• Electrical driers and furnaces with precision temperature and vacuum control.
• Infra-red, UV Vis and Raman spectroscopy, HPLC.
• Scratch tester.
• Micro-macro hardness tester.
• Planetary Mills.

Dr. Vamsi Krishna Balla
Chief Scientist and Head
Phone: +91-(033) 2322 3219
Fax: +91-33-24730957
E-mail: vamsiballa@cgcri.res.in