In a globally aging society, synthetic bone blocks are
in increasing
demand. An ideal synthetic bone block fuses early with bone and is
replaced with new bone at a suitable speed while withstanding the
weight load. Herein, we report carbonate apatite honeycomb (HC) blocks
with superior mechanical strength, osteoconductivity, and bioresorbability
compared to a clinically used synthetic porous block (control block).
Three types of HC blocks were fabricated via the debinding of HC green
bodies at 600, 650, and 700 °C and subsequent phosphatization,
designated as HC-600, HC-650, and HC-700, respectively. The macropores
in these HC blocks uniaxially penetrated the blocks, whereas those
in the control block were not interconnected. Consequently, the HC
blocks exhibited higher open macroporosities (18%–20%) than
the control block (2.3%). In contrast, the microporosity of the control
block (46.4%) was higher than those of the HC blocks (19%–30%).
The compressive strengths of the HC-600, HC-650, HC-700, and control
blocks were 24.7, 43.7, 103.8, and 38.9 MPa, respectively. The HC
and control blocks were implanted into load-bearing segmental bone
defects of rabbit ulnae. Uniaxial HC macropores enabled faster bone
ingrowth than the poorly interconnected macropores in the control
block. Microporosity in the HC blocks affected bone formation and
osteoclastic resorption over a period of 24 weeks. The resorption
of HC-650 corresponded to new bone formation; therefore, new bone
with strength equal to that of the original bone bridged the separated
bones. Thus, the HC blocks achieved the reconstruction of segmental
bone defects while withstanding the weight load. The findings of this
study contribute to the design and development of synthetic bone blocks
for reconstructing segmental defects.