A critical review on advanced functional bioceramics fabricated by SLA for precision implant applications Palivela Bhargav Chandan, Amrit Raj Paul, Mohit Kumar Sahu, Dinesh Kalyanasundaram, Suresh Kumar Bhargava Journal of Materials Research and Technology, 2026 The convergence of advanced bioceramics and stereolithography (SLA)-based additive manufacturing (AM) is redefining the design and fabrication of precision biomedical implants. Conventional ceramic processing routes, while mature, are fundamentally constrained in producing patient-specific geometries, hierarchical porosity, and functionally graded architectures essential for next-generation regenerative applications. SLA, a vat-photopolymerization technique, offers unparalleled resolution, geometric freedom, and microarchitectural control, enabling the fabrication of complex bio-ceramic constructs with tunable biological and mechanical performance. This review critically examines recent advancements in SLA-based manufacturing of functional bioceramics, including hydroxyapatite, β-tricalcium phosphate, zirconia, alumina, bioglass, and composite systems. Particular emphasis is placed on the interdependence between slurry formulation (solid loading, rheology, dispersant chemistry, photo initiator systems), photopolymerization dynamics, and post-processing strategies such as debinding and sintering. The manuscript systematically correlates printing parameters—including laser power, exposure energy, scanning speed, and layer thickness—with microstructural features, porosity, dimensional shrinkage, and mechanical integrity of the final constructs. Emerging innovations such as digital light processing (DLP), two-photon polymerization (TPP), multi-material printing, and AI-assisted process monitoring are also discussed in the context of improving reproducibility and clinical scalability. Furthermore, the biomedical relevance of SLA-fabricated bioceramics is analyzed through applications in bone tissue engineering, dental restorations, and craniofacial implants, highlighting the ability to engineer bioactivity, osteoconductivity, and controlled resorption profiles through architectural design and surface functionalization. Persistent challenges—including light scattering in highly loaded slurries, defect formation during thermal processing, and the balance between porosity and mechanical strength—are critically evaluated. By consolidating material science, processing optimization, and biomedical performance considerations, this review provides a strategic roadmap for advancing SLA-enabled bioceramic technologies toward reliable, high-performance, and clinically translatable precision implant systems.
Development of Polymer–Metal Screw System for Bone Fracture Repair: Combining Strength and Biocompatibility Ranveer Kaur, Sunil Kumar Yadav, Vivek Yadav, Arnab Sikidar, Sanyog Jain, Dinesh Kalyanasundaram ACS Biomaterials Science and Engineering, 2025 Bone screws and plates are either made of metals (such as titanium grade 5 alloy or magnesium alloy) or polymers (such as polylactide- co -glycolide, poly- l -lactide, or polyurethane) and are used for the treatment of bone fractures. However, these metallic/polymeric orthopedic products also exhibit several complications, including bone tissue damage, stress shielding, metallosis, and inadequate stability of polymers. We aimed to create a polymer–metal screw system to fix the problems associated with conventional screws in fracture surgery, and in this context, the polymer–metal screw system was designed and manufactured by the authors. The screw system consists of a biomedical grade polymer, either polylactic acid (PLA) or polyurethane (PU) along with a metallic insert made of titanium grade 5 (Ti6Al4V) alloy. The screw’s design is protected by a patent publication number US2022/0000529A1. Two sets of polymeric screws were manufactured via injection molding from PLA and PU pellets. The Ti6Al4V metallic insert was placed in both screw sets. The screws were evaluated for the torque required to insert the screw into a polyurethane block and the strength required to pull out the screw from the block using a tension-torque universal testing machine. Also, its bending strength was evaluated and compared with those of titanium screws and polymeric screws without an inner metallic insert. To investigate the proposed screw’s ability against bending force under in vivo cyclic bending loads, a bending fatigue test was also performed. The biocompatibility of the screws was evaluated via in vitro cell culture on human osteosarcoma cells and in vivo animal studies on Sprague–Dawley rats, as per ISO 10993. Follow-up investigations were conducted on days 7 and 14 after implantation. The polymeric outer screw exhibited optimum results for driving torque (266.14 ± 46.93 N·mm), pullout force (158.66 ± 9.75 N), and bending (static and fatigue) tests. The PLA outer screw exhibited a static bending strength of 153.8 ± 9.6 MPa, which was approximately 89.9% lower than that of the titanium screw. However, with the inclusion of an inner metallic insert, the bending strength of the PLA outer screw rose significantly from 153.8 ± 9.6 MPa to 531.7 ± 32.5 MPa, thereby reducing the difference with the titanium screw by approximately 65.1%. The screw with an inner metallic insert demonstrated a fatigue strength of 211.8 MPa and a fatigue life of 70,143 cycles. In vitro cell culture studies showed the cytocompatibility of both polymeric screws with the human osteosarcoma cell line. Cell adhesion on the surface of the screw and its morphology were similar to the control untreated cells, as depicted by fluorescence microscopy. No acute systemic toxicity was observed for both PLA and PU screw samples in in vivo studies on rats as biomarkers for hepatotoxicity, and nephrotoxicity biomarkers were observed within the normal range by diagnostic tests. Histopathological evaluation showed better bone growth around the PLA and PU screw implant sections compared to sections of commercially available titanium bone screws. The authors have developed a polymer–metal screw system that addresses the drawbacks of current metallic and polymeric orthopedic products. The screw system has been mechanically characterized, evaluated for biological safety, and shown to be compatible with both in vitro and in vivo evaluations. Overall, the polymer–metal screw system is a promising new orthopedic product with the potential to improve the treatment of bone fractures.
Evaluation of Fatigue Life of Additively Manufactured Ti6Al4V Neovius Lattices in Simulated Body Fluid for Biomedical Applications Sonu Singh, Jivesh Jain, Sunil Kumar Yadav, Prashant Kumar, Vijay Kumar Meena, Priya Vashisth, Dinesh Kalyanasundaram Advanced Engineering Materials, 2025 Additive manufacturing (AM) using laser powder bed fusion (LPBF) enables the fabrication of intricate biomimetic structures, such as triply periodic minimal surfaces (TPMS), which hold significant potential for biomedical implants. However, the fatigue performance of these structures is often compromised by surface roughness and internal defects. In this work, Triply periodic minimal surface (TPMS) based lattices were fabricated using the LPBF process. Quasi‐static compression tests and computational fluid dynamics (CFD) simulations were conducted to determine mechanical properties. and to evaluate permeability and wall shear stress of the lattices respectively. Moreover, High‐cycle fatigue testing under compression‐compression cyclic loading was performed to determine endurance limits. To further improve its endurance limit, surface modification was carried out using shot peening. Additionally, the influence of a simulated physiological environment on fatigue behaviour was assessed by testing fatigue in Simulated Body Fluid (SBF). Results revealed that surface modification increased the endurance limit under ambient conditions by 20%. However, fatigue testing in SBF revealed a 32% reduction in the endurance limit of surface‐modified samples, emphasizing the detrimental effects of physiological conditions. These findings highlight the importance of surface modification and environmental factors in the design of biomimetic implants.
The synergistic effect and origin of strength in carbon fiber reinforced PAEK, PEEK, and PEKK high-performance thermoplastic composites manufactured by multi-scale aqueous dispersion coating V. Balakumaran, Ramasamy Alagirusamy, Dinesh Kalyanasundaram Polymer Composites, 2024 High‐performance thermoplastic composites of polyketones [poly‐aryl‐ether‐ketone (PAEK), poly‐ether‐ether‐ketone (PEEK), poly‐ether‐ketone‐ketone (PEKK)] reinforced with continuous carbon fiber (CF) were consolidated using towpreg produced by multi‐scale aqueous dispersion coating technique. An intra‐matrix trend of composite strength and void fraction was studied to identify the composite with maximum strength free of voids for each polyketone matrix. The CF/PAEK composite with a flexural strength of ~2047 MPa and ILSS of ~99 MPa with a fiber volume fraction of ~67% had the maximum strength free of voids among CF/PAEK composite and all polyketone composites studied. The highest crystallinity (34.5%), and the highest amount of hydrogen bonding and bonds formed between CF, PI nanoparticle, and PAEK explained the origin of strength in CF/PAEK composite. The maximum strength among CF/PEEK and CF/PEKK composite free of voids had a flexural strength of ~1861 MPa, ~1981 MPa; ILSS of ~74 MPa, ~60 MPa; fiber volume fraction of ~61% and ~ 65%, respectively. The polyimide (PI) nanoparticles layer on CF formed the fiber matrix interface, supported hydrogen bonding in all polyketone composites, and formed bonds with CF and matrices of PAEK and PEEK establishing a synergistic effect.Highlights Intra‐matrix trend of strength and voids in polyketone composites studied. Void‐free, high‐performance, high fiber volume fraction composites developed. CF/PAEK composite had maximum strength among polyketone composites studied. PI nanoparticles formed bonds with CF and matrices of PAEK and PEEK. CF/PAEK composite strength originates from crystallinity, H bond, and bonding.
Bridging biomimetic and bioenergetics scaffold: Cellulose-graphene oxide-arginine functionalized aerogel for stem cell-mediated cartilage repair Puneet Pareek, Shivani Chaudhary, Sonu Singh, Aiswarya Thattaru Thodikayil, Dinesh Kalyanasundaram, Sachin Kumar International Journal of Biological Macromolecules, 2024 The avascular nature of cartilage tissue limits inherent regenerative capacity to counter any damage and this has become a substantial burden to the health of individuals. As a result, there is a high demand to repair and regenerate cartilage. Existing tissue engineering approaches for cartilage regeneration typically produce either microporous or nano-fibrous scaffolds lacking the desired biological outcome due to lack of biomimetic dual architecture of microporous construct with nano-fibrous interconnected structures like the native cartilage. Most of these scaffolds also fail to suppress ROS generation and provide sustained bioenergetics to cells, resulting in the loss of metabolic activity under avascular microenvironment of cartilage. A dual architecture microporous construct with nano-fibrous interconnected network of cellulose aerogel reinforced with arginine-coated graphene oxide (CNF-GO-Arg aerogel) was developed for cartilage regeneration. The designed dual-architectured CNF-GO-Arg aerogel using dual ice templating assembly demonstrates 80 % strain recovery ability under compression. The release of Arginine from CNF-GO-Arg aerogel supported 41 % reduction in intracellular ROS activity and promoted chondrogenic differentiation of hMSCs by shifting mitochondrial bioenergetics towards oxidative phosphorylation indicated by JC-1 dye staining. Overall developed CNF-GO-Arg aerogel provided multifunctionality via biomimetic morphology, cellular bioenergetics, and suppressed ROS generation to address the need for regeneration of cartilage.
Electric field enabled manipulation of CNT alignment in epoxy matrix: Methodology and mechanical characterization Eccm 2018 18th European Conference on Composite Materials, 2020
Authors' response Pradnya Patil, Om Prakash Kharbanda, Ritu Duggal, Taposh K. Das, Dinesh Kalyanasundaram American Journal of Orthodontics and Dentofacial Orthopedics, 2015
Immunosensor towards low-cost, rapid diagnosis of tuberculosis Jong-Hoon Kim, Woon-Hong Yeo, Zhiquan Shu, Scott D. Soelberg, Shinnosuke Inoue, Dinesh Kalyanasundaram, John Ludwig, Clement E. Furlong, James J. Riley, Kris M. Weigel, Gerard A. Cangelosi, Kieseok Oh, Kyong-Hoon Lee, Dayong Gao, Jae-Hyun Chung Lab on A Chip, 2012
Highly sensitive and specific microtip-immunofluorescence sensor for rapid TB diagnosis 15th International Conference on Miniaturized Systems for Chemistry and Life Sciences 2011 Microtas 2011, 2011
Application of chemical transformation induced fracture for cutting of superhard materials Transactions of the North American Manufacturing Research Institution of SME, 2011
Development of an equimolar high entropy MgTiCuZrNb alloy and its exposure to a wide range of acidic and alkaline solutions D Pal, D Kumar, D Kalyanasundaram Electrochimica Acta, 148802 , 2026 2026
A critical review on advanced functional bioceramics fabricated by SLA for precision implant applications PB Chandan, AR Paul, MK Sahu, D Kalyanasundaram, SK Bhargava Journal of Materials Research and Technology , 2026 2026 Citations: 2
Sculpting the mandible: Indigenous CAD-CAM versus traditional free fibula planning–An Institutional experience A Moideen, CA Singh, A Thakar, R Kumar, K Sikka, R Kumar, S Panda, ... Radiotherapy and Oncology 216, S53-S54 , 2026 2026
Development of polymer-metal screw system for bone fracture repair: Combining Strength and Biocompatibility R Kaur, SK Yadav, V Yadav, A Sikidar, S Jain, D Kalyanasundaram ACS Biomaterials Science & Engineering , 2025 2025
Characterization of polyhydroxybutyrate (PHB) sustainably produced by Alcaligenes faecalis utilizing lactic acid as a renewable substrate A Dhawan, D Kalyanasundaram, PK Manna, FM Pfeffer, HB Bohidar, ... International Journal of Biological Macromolecules, 147462 , 2025 2025
Evaluation of fatigue life of additively manufactured Ti6Al4V neovius lattices in simulated body fluid for biomedical applications S Singh, J Jain, SK Yadav, P Kumar, VK Meena, P Vashisth, ... Advanced Engineering Materials 27 (7), 2402368 , 2025 2025 Citations: 5
Graphene-sponges containing multi-walled carbon nanotubes for electrosorption of salt-ions R Patil, D Jiang, X Xu, N Kumar, S Bhattacharjee, SK Yadav, ... Chemical Engineering Journal 506, 159270 , 2025 2025 Citations: 15
Bush bearing materials and their fabrication aspects along with techniques used for performance improvement: a review with prospects NS Jammoria, RK Pandey, D Kumar, D Kalyanasundaram 대한기계학회 춘추학술대회, 1037-1037 , 2024 2024
Feasibility study for replacement of babbitt coating by textured surface in a bush bearing NS Jammoria, RK Pandey, D Kumar, D Kalyanasundaram 대한기계학회 춘추학술대회, 990-990 , 2024 2024
Development of quaternary ammonium based acrylic copolymer antimicrobial coatings for polyurethane tracheoesophageal voice prostheses M Singh, A Afreen, M Anees, D Kalyanasundaram, H Singh, N Bhatnagar Journal of Materials Chemistry B , 2024 2024 Citations: 2
Bridging Biomimetic and Bioenergetics Scaffold: Cellulose-Graphene Oxide-Arginine Functionalized Aerogel for Stem Cell-Mediated Cartilage Repair P Pareek, S Chaudhary, S Singh, A Thattaru Thodikayil, ... International Journal of Biological Macromolecules , 2024 2024 Citations: 6
The synergistic effect and origin of strength in carbon fiber reinforced PAEK, PEEK, and PEKK high-performance thermoplastic composites manufactured by multi-scale aqueous … V Balakumaran, R Alagirusamy, D Kalyanasundaram Polymer Composites , 2024 2024 Citations: 9
Nanosecond Laser Induced Periodic Silicon Microstructures for Broadband Antireflective Applications A Kuriakose, P Malik, JN Acharyya, D Kalyanasundaram, P Srivastava, ... Optics & Laser Technology , 2024 2024 Citations: 7
Development of iodine based sustained release antimicrobial coatings for polyurethane voice prostheses M Singh, M Anees, A Afreen, D Kalyanasundaram, N Bhatnagar, H Singh Journal of Materials Chemistry B , 2024 2024 Citations: 1
Effect of Heat Treatment on Material property and Cell Viability of Wire Arc Additively Manufactured Ti6Al4V A Paul, S Singh, J Hirwani, S Yadav, C Dekiwadia, M Mukherjee, ... ACS Applied Bio Materials , 2024 2024 Citations: 3
Transitional and refractory elements-based high entropy alloy developed through mechanical alloying and microwave sintering: Tribological and corrosion responses NV Abhijith, S Phutela, D Kumar, D Kalyanasundaram Vacuum , 2024 2024 Citations: 19
Rapid detection of Mucorales in human blood and urine samples by functionalised Heusler magnetic nanoparticle assisted customized loop mediated isothermal amplification R Roy, G Singh, UR Dahiya, M Pandey, I Xess, D Kalyanasundaram Medical Mycology , 2024 2024 Citations: 10
Evaluation of the stresses on the knee meniscus tissue under various loading conditions and correlation with resulting meniscal tears observed clinically: A Finite Element Study RS Pawar, S Yadav, D Kalyanasundaram Journal of the Brazilian Society of Mechanical Sciences and Engineering , 2024 2024 Citations: 5
Nanotextured and drug loaded Neovius Ti6Al4V ELI scaffolds with osteogenesis and anticancer potential S Singh, R Roy, V Meena, P Vashisth, D Kalyanasundaram Materials & Design , 2024 2024 Citations: 9
Carbon Quantum Dot-Nanocomposite Hydrogel as Denovo Nexus in Rapid Chondrogenesis M Majood, O Agarwal, P Garg, A Selvam, SK Yadav, S Singh, ... Biomaterials Advances , 2024 2024 Citations: 10
MOST CITED SCHOLAR PUBLICATIONS
A review on biomechanics of anterior cruciate ligament and materials for reconstruction M Marieswaran, I Jain, B Garg, V Sharma, D Kalyanasundaram Applied bionics and biomechanics , 2018 2018 Citations: 258
Outcome and safety analysis of 3D printed patient specific pedicle screw jigs for complex spinal deformities: A comparative study B Garg, M Gupta, M Singh, D Kalyanasundaram The Spine Journal , 2019 2019 Citations: 136
Machining damage in FRPs: laser versus conventional drilling A Hejjaji, D Singh, S Kubher, D Kalyanasundaram, S Gururaja Composites Part A: Applied Science and Manufacturing 82, 42-52 , 2016 2016 Citations: 132
Immunosensor towards low-cost, rapid diagnosis of tuberculosis JH Kim, WH Yeo, Z Shu, SD Soelberg, S Inoue, D Kalyanasundaram, ... Lab on a Chip 12 (8), 1437-1440 , 2012 2012 Citations: 70
Self functionalized ultrastable water suspension of luminescent carbon quantum dots A Singh, PK Mohapatra, D Kalyanasundaram, S Kumar Materials Chemistry and Physics , 2019 2019 Citations: 60
Improvement of Deep Groove Ball Bearing’s Performance Using a Bionic Textured Inner Race KEC Vidyasagar, RK Pandey, D Kalyanasundaram Journal of Bionic Engineering 18 (4), 974-990 , 2021 2021 Citations: 58
Tribodynamic studies of textured gearsets lubricated with fresh and MoS2 blended greases N Gupta, N Tandon, RK Pandey, KEC Vidyasagar, D Kalyanasundaram Tribology International , 2021 2021 Citations: 58
Surface deterioration and elemental composition of retrieved orthodontic miniscrews P Patil, OP Kharbanda, R Duggal, TK Das, D Kalyanasundaram American Journal of Orthodontics and Dentofacial Orthopedics 147 (4), S88-S100 , 2015 2015 Citations: 58
An exploration of frictional and vibrational behaviors of textured deep groove ball bearing in the vicinity of requisite minimum load KEC Vidyasagar, RK Pandey, D Kalyanasundaram Friction , 2021 2021 Citations: 54
Enhancement of open hole tensile strength via alignment of carbon nanotubes infused in glass fiber - epoxy - CNT multi-scale composites J Pothnis, D Kalyanasundaram, S Gururaja Composites Part A: Applied Science and Manufacturing 140, 106155 , 2021 2021 Citations: 54
Influence of various forms of polypropylene matrix (fiber, powder and film states) on the flexural strength of carbon-polypropylene composites V Goud, R Alagirusamy, A Das, D Kalyanasundaram Composites Part B: Engineering , 2019 2019 Citations: 52
An affordable insole-sensor-based trans-femoral prosthesis for normal gait S Pandit, AK Godiyal, AK Vimal, U Singh, D Joshi, D Kalyanasundaram Sensors 18 (3), 706 , 2018 2018 Citations: 52
Highly-sensitive detection of Salmonella typhi in clinical blood samples by magnetic nanoparticle-based enrichment and in-situ measurement of isothermal amplification of … A Kaur, A Kapil, R Elangovan, S Jha, D Kalyanasundaram PLOS One 13 (9), e0203982 , 2018 2018 Citations: 50
Design and validation of a hybrid laser/water-jet machining system for brittle materials D Kalyanasundaram, G Shehata, C Neumann, P Shrotriya, P Molian Journal of Laser Applications 20 (2), 127-134 , 2008 2008 Citations: 50
Experimental assessment of biomechanical properties in human male elbow bone subjected to bending and compression loads D Singh, A Rana, SK Jhajhria, B Garg, PM Pandey, D Kalyanasundaram Journal of applied biomaterials and functional materials , 2019 2019 Citations: 46
Investigation, modelling and validation of material separation mechanism during fiber laser machining of medical grade titanium alloy Ti6Al4V and stainless steel SS316L V Parmar, A Kumar, G Vijaya Prakash, S Datta, D Kalyanasundaram Mechanics of Materials , 2019 2019 Citations: 44
A review of biomarkers in peri-miniscrew implant crevicular fluid (PMICF) A Kaur, OP Kharbanda, P Kapoor, D Kalyanasundaram Progress in orthodontics 18 (1), 42 , 2017 2017 Citations: 44
Open hole fatigue testing of laser machined MD-CFRPs D Kalyanasundaram, S Gururaja, P Prabhune, D Singh Composites Part A: Applied Science and Manufacturing 111, 33-41 , 2018 2018 Citations: 43
Oxidation facilitated antimicrobial ability of laser micro-textured titanium alloy against gram-positive staphylococcus aureus for biomedical applications V Parmar, A Kumar, MM Sankar, S Datta, GV Prakash, S Mohanty, ... Journal of laser applications 30, 032001 , 2018 2018 Citations: 43
Development of single stage TiNbMoMnFe high entropy alloy coating on 304L stainless steel using HVOF thermal spray NV Abhijith, D Kumar, D Kalyanasundaram Journal of Thermal Spray Technology , 2022 2022 Citations: 42