The introduction of nanoparticles
(NPs) into the breath-figure-templated self-assembly (BFTSA) process
is an increasingly common method to selectively decorate a surface
porous structure. In the field of prosthetic devices, besides controlling
the morphology and roughness of the structure, NPs can enhance the
osteointegration mechanism because of their specific ion release.
Among the most widely used NPs, there are silica and hydroxyapatite
(HAp). In this work, we propose a novel one-stage method to fabricate
NP-decorated surface porous structures that are suitable for prosthetic
coating applications. This technique combines the classical direct
BFTSA process with the cavitation effect induced by an ultrasonic
atomizer that generates a mist of water droplets with embedded NPs.
Coatings were successfully obtained by combining a UV cross-linkable
polymer precursor, alkoxy silicone, with synthesized HAp NPs, on Ti6Al4V
alloy discs. The cross-linked polymeric surface porous structures
at selected concentrations were then pyrolyzed in an ammonia atmosphere
to obtain a silicon oxynitride (SiON) ceramic coating. Herein, we
report the chemical and morphological analyses of both the polymeric
and ceramic coatings as well as the effect of NPs at the interface.