Influence of manufacturing parameters on bioactive glass 45S5: Structural analysis and applications in bone tissue engineering

Bioactive glass (BG-45S5) production through the melting process is affected by a wide variety of parameters. This study investigated the synthesis of BG-45S5 granules and the process variables to produce a bioactive and osteoinductive BG for bone grafting applications. The melting process was initially analyzed by varying parameters such as crucible type and pouring environment using P2O5 as phosphorus precursor. The obtained products were characterized by crystalline phases, characteristic chemical groups, particle size distribution, and chemical composition. Materials poured into graphite or steel molds resulted in particle sizes more suitable for applications in granular form. Using a platinum crucible yielded a chemical composition closer to the target when compared with another ceramic crucible. Subsequently, the melting process was evaluated to different phosphorus precursor (P2O5 or Na2HPO4) and melting duration (1 or 2 h) in a platinum crucible verifying their effects on the thermal behavior, chemical composition and structure of BG-45S5. Employing Na2HPO4 as a precursor led to higher glass transition and crystallization temperatures as compared to P2O5, enhancing glass homogeneity and structural stability. The product with better characteristics in terms of composition and structure was further characterized for bioactivity and cell culture behavior, showing a greater amount of mineralization nodules when compared to commercial hydroxyapatite. This is particularly due to its behavior as the solubility and interaction in biological environments.