Crosslinkable 3D printed biomaterial-based implants and methods of manufacture thereof

1. A biomaterial-based implant formed under a mild crosslinking condition wherein the mild crosslinking condition is selected from the group consisting of a visible light exposure, an ultraviolet exposure and combinations thereof, wherein at least one pre-implantation property selected from the group consisting of a cohesion, a shape, and a size of the biomaterial-based implants is within between about 60% to about 100% of the at least one preimplantation property for up to about five years following formation of the implant and wherein the biomaterial-based implant retains greater than 80% of at least one biological activity selected from the group consisting of an osteoconductivity, an osteoinductivity, a chondroinductivity, a cellular recruitment, and a cell differentiation, and wherein the biomaterial-based implant comprises between two layers and about 50,000 layers of the biomaterial, wherein the biomaterial comprises a bone and a polymer, wherein the polymer is a biocompatible polymer, a biodegradable polymer or a combination thereof.

2. The implant of claim 1 , wherein the biomaterial-based implant ranges in thickness from about 0.1 mm to 100 mm, ranges in length from about 5 mm to 50 cm, and ranges in width from about 5 mm to 50 cm.

3. The implant of claim 1 , wherein the biomaterial of the implant further comprises a material selected from the group consisting of a connective tissue, a tendon, a pericardium, a dermis, a cornea, a dura matter, a fascia, a heart valve, a ligament, a capsular graft, a cartilage, a collagen, a nerve, a placental tissue, and combinations thereof.

4. The implant of claim 1 , wherein the bone is at least one of a cortical bone, a cancellous bone, or a corticocancellous bone.

5. The implant of claim 1 , wherein the bone is at least one of a demineralized bone, a partially demineralized bone, or a fully mineralized bone.

6. The implant of claim 1 , wherein the biomaterial is combined with at least one of a crosslinkable material, an additive, a binder, and a solvent.

7. The implant of claim 1 , wherein the polymer is the biodegradable polymer and wherein the biodegradable polymer is selected from the group consisting of a crosslinkable polycaprolactones, a polyethylene glycols, a polyhydroxyalkanoates, a polyesteramides, a polylactides, a polyglycolides, a poly(lactide-co-glycolide)s, a polyorthoesters, a polyoxazolines, a polyurethanes, combinations, and crosslinkable derivatives thereof.

8. The implant of claim 1 , wherein the polymer is a biodegradable polymer and provides gradual release of at least one additive from the biomaterial-based implant following implantation.

9. A three-dimensional printed biomaterial-based implant formed under a mild crosslinking condition wherein the mild crosslinking condition is selected from the group consisting of a visible light exposure, an ultraviolet exposure and combinations thereof, and wherein the three-dimensional printed biomaterial-based implant is produced with a three-dimensional printer, comprising:

a biomaterial comprises a bone and further comprises at least one of a connective tissue, a tendon, a pericardium, a dermis, a cornea, a dura matter, a fascia, a heart valve, a ligament, a capsular graft, a cartilage, a collagen, a nerve, and a placental tissue;

a crosslinking material, wherein the crosslinkable material is selected from the group consisting of a biodegradable polymer, a biocompatible polymer, and combinations thereof;

a thickness of between about 0.1 mm to 100 mm;

a length of between about 5 mm to 50 cm;

a width of between about 5 mm to 50 cm;

at least 80% of at least one biological activity selected from the group consisting of an osteoconductivity, an osteoinductivity, an chondroinductivity, a cellular recruitment, and a cell differentiation; and

between 60% to about 100% of at least one pre-implantation property selected from the group consisting of a cohesion, a shape, and a size of the biomaterial-based implants, wherein the at least one preimplantation property is maintained for up to about five years following formation of the implant, and wherein the biomaterial-based implant comprises between two layers and about 50,000 layers of the biomaterial.

10. The implant of claim 9 , further comprising at least one of a native growth factor or an intrinsic growth factor.

11. The implant of claim 9 , wherein the bone is selected from the group consisting of a cortical bone, a cancellous bone, and a corticocancellous bone.

12. The implant of claim 9 , wherein the bone is a demineralized bone, a partially demineralized bone, a fully mineralized bone, or combinations thereof.

13. The implant of claim 9 , wherein the bone is at least partially demineralized and wherein a residual calcium content of the bone is less than or equal to about 8%.

14. The implant of claim 9 , wherein the crosslinking material is the biodegradable polymer selected from the group consisting of a polycaprolactone, a polyethylene glycol, a polyhydroxyalkanoate, a polyesteramide, a polylactide, a polyglycolide, a poly(lactide-co-glycolide), a polyorthoester, a polyoxazoline, a polyurethane, and copolymers thereof.

15. The implant of claim 9 , further comprising an additive, a binder, a solvent, or combinations thereof.

16. The implant of claim 9 , further comprising between about 0 wt. % to about 50 wt. % of an additive in the total weight of the biomaterial, wherein the additive is selected from the group consisting of a bioactive agent, a biocompatible mineral, and combinations thereof.

17. The implant of claim 16 , wherein the additive is the bioactive agent and selected from the group consisting of an antibiotic, an anti-infective agent, and combinations thereof.

18. The implant of claim 17 , wherein the bioactive agent is the anti-infective agent and is selected from the group consisting of a silver sulfadiazine, a chlorhexidine, a gentamicin, a tobramycin, a vancomycin, and combinations thereof.

19. The implant of claim 9 , further comprising at least one of a hormone, a growth factor, or a cell.

20. The implant of claim 9 , further comprising up to about 75 wt. % of a binding agent.

21. A three-dimensional printed biomaterial-based implant, comprising:

a biomaterial comprises a bone and further comprises at least one of a connective tissue, a tendon, a pericardium, a dermis, a cornea, a dura matter, a fascia, a heart valve, a ligament, a capsular graft, a cartilage, a collagen, a nerve, a placental tissue, and combinations thereof;

a crosslinking material, wherein the crosslinkable material is selected from the group consisting of a biodegradable polymer, a biocompatible polymer, and combinations thereof;

at least one of an additive, a hormone, or a binder; and

at least one of a native growth factor or an intrinsic growth factor;

wherein a thickness of the implant is between about 0.1 mm to 100 mm;

wherein a length of the implant is between about 5 mm to 50 cm;

wherein a width of the implant is between about 5 mm to 50 cm;

wherein at least 80% of at least one biological activity selected from the group consisting of an osteoconductivity, an osteoinductivity, a chondroinductivity, a cellular recruitment, and a cell differentiation;

wherein between 60% to about 100% of at least one pre-implantation property selected from the group consisting of a cohesion, a shape, and a size of the biomaterial-based implants, wherein the at least one preimplantation property is maintained for up to about five years following formation of the implant; and

wherein the biomaterial-based implant comprises between two layers and about 50,000 layers of the biomaterial.

22. The implant of claim 21 , wherein the crosslinking material is the biodegradable polymer selected from the group consisting of a polycaprolactone, a polyethylene glycol, a polyhydroxyalkanoate, a polyesteramide, a polylactide, a polyglycolide, a poly(lactide-co-glycolide), a polyorthoester, a polyoxazoline, a polyurethane, and copolymers thereof.

23. The implant of claim 21 , wherein the binder is selected from the group consisting of a binder polymer, a glue, a gum, a sugar, a cellulose ether, a resin and combinations thereof.