Synthetic, bioactive ultra-porous bone graft materials having an engineered porosity, and implants formed from such materials are provided. In particular, these implants comprise bioactive glass and incorporate allograft material for osteoinduction. The implants are suitable for bone tissue regeneration and/or repair.

This invention includes malleable, biodegradable, fibrous compositions for application to a tissue site in order to promote or facilitate new tissue growth. One aspect of this invention is a fibrous component that provides unique mechanical and physical properties. The invention may be created by providing a vessel containing a slurry, said slurry comprising a plurality of natural or synthetic polymer fibers and at least one suspension fluid, wherein the polymer fibers are substantially evenly dispersed and randomly oriented throughout the volume of the suspension fluid; applying a force, e.g., centrifugal, to said vessel containing said slurry, whereupon said force serves to cause said polymer fibers to migrate through the suspension fluid and amass at a furthest extent of the vessel, forming a polymer material, with said polymer material comprising polymer fibers of sufficient length and sufficiently viscous, interlaced, or interlocked to retard dissociation of said polymer fibers.

This invention includes malleable, biodegradable, fibrous compositions for application to a tissue site in order to promote or facilitate new tissue growth. One aspect of this invention is a fibrous component that provides unique mechanical and physical properties. The invention may be created by providing a vessel containing a slurry, said slurry comprising a plurality of natural or synthetic polymer fibers and at least one suspension fluid, wherein the polymer fibers are substantially evenly dispersed and randomly oriented throughout the volume of the suspension fluid; applying a force, e.g., centrifugal, to said vessel containing said slurry, whereupon said force serves to cause said polymer fibers to migrate through the suspension fluid and amass at a furthest extent of the vessel, forming a polymer material, with said polymer material comprising polymer fibers of sufficient length and sufficiently viscous, interlaced, or interlocked to retard dissociation of said polymer fibers.

This invention includes malleable, biodegradable, fibrous compositions for application to a tissue site in order to promote or facilitate new tissue growth. One aspect of this invention is a fibrous component that provides unique mechanical and physical properties. The invention may be created by providing a vessel containing a slurry, said slurry comprising a plurality of natural or synthetic polymer fibers and at least one suspension fluid, wherein the polymer fibers are substantially evenly dispersed and randomly oriented throughout the volume of the suspension fluid; applying a force, e.g., centrifugal, to said vessel containing said slurry, whereupon said force serves to cause said polymer fibers to migrate through the suspension fluid and amass at a furthest extent of the vessel, forming a polymer material, with said polymer material comprising polymer fibers of sufficient length and sufficiently viscous, interlaced, or interlocked to retard dissociation of said polymer fibers.

A method and a composite material used for free forming a bone substitute are provided. The composite material comprises a support cloth, and a partially hardened bone paste coated on the support cloth. The bone paste contains a mixture of calcium sulfate and calcium phosphate in a weight ratio of 1:1 to 1:4. The bone substitute can be made by laminating the composite material either on a bone model or not.

A method and a composite material used for free forming a bone substitute are provided. The composite material comprises a support cloth, and a partially hardened bone paste coated on the support cloth. The bone paste contains a mixture of calcium sulfate and calcium phosphate in a weight ratio of 1:1 to 1:4. The bone substitute can be made by laminating the composite material either on a bone model or not.

A method and a composite material used for free forming a bone substitute are provided. The composite material comprises a support cloth, and a partially hardened bone paste coated on the support cloth. The bone paste contains a mixture of calcium sulfate and calcium phosphate in a weight ratio of 1:1 to 1:4. The bone substitute can be made by laminating the composite material either on a bone model or not.

A bone-regeneration material that contains calcium phosphate particles in a biodegradable fiber containing PLGA by using electrospinning. A PLGA resin is heated in a kneader to soften until the viscosity of the resin becomes 10.sup.2 to 10.sup.7 Pa.Math.s. A powder of calcium phosphate fine particles is added and mixed with the softened PLGA resin, while the blade of the kneader rotates. The mixture is kneaded by applying thermal and mechanical energy to the mixture through the continuous rotation of the blade of the kneader in the heated state, and aggregations of the calcium phosphate fine particles are disintegrated to prepare a composite in which the calcium phosphate fine particles are dispersed in the PLGA resin. The composite is dissolved in a solvent to prepare a spinning solution. Electrospinning is performed on the spinning solution to manufacture biodegradable fibers having therein the calcium phosphate fine particles substantially uniformly dispersed.

A bone-regeneration material that contains calcium phosphate particles in a biodegradable fiber containing PLGA by using electrospinning. A PLGA resin is heated in a kneader to soften until the viscosity of the resin becomes 10.sup.2 to 10.sup.7 Pa.Math.s. A powder of calcium phosphate fine particles is added and mixed with the softened PLGA resin, while the blade of the kneader rotates. The mixture is kneaded by applying thermal and mechanical energy to the mixture through the continuous rotation of the blade of the kneader in the heated state, and aggregations of the calcium phosphate fine particles are disintegrated to prepare a composite in which the calcium phosphate fine particles are dispersed in the PLGA resin. The composite is dissolved in a solvent to prepare a spinning solution. Electrospinning is performed on the spinning solution to manufacture biodegradable fibers having therein the calcium phosphate fine particles substantially uniformly dispersed.

A bone-regeneration material that contains calcium phosphate particles in a biodegradable fiber containing PLGA by using electrospinning. A PLGA resin is heated in a kneader to soften until the viscosity of the resin becomes 10.sup.2 to 10.sup.7 Pa.Math.s. A powder of calcium phosphate fine particles is added and mixed with the softened PLGA resin, while the blade of the kneader rotates. The mixture is kneaded by applying thermal and mechanical energy to the mixture through the continuous rotation of the blade of the kneader in the heated state, and aggregations of the calcium phosphate fine particles are disintegrated to prepare a composite in which the calcium phosphate fine particles are dispersed in the PLGA resin. The composite is dissolved in a solvent to prepare a spinning solution. Electrospinning is performed on the spinning solution to manufacture biodegradable fibers having therein the calcium phosphate fine particles substantially uniformly dispersed.