Stereolithographic fabrication of gyroid-structured β-tricalcium phosphate scaffolds from solvent-based slurries

High-solid-loading β-tricalcium phosphate (β-TCP) slurries (up to 50 vol%) were formulated for stereolithography of solvent-based ceramic slurries (3S), enabling the fabrication of gyroid-structured β-TCP scaffolds with controlled porous architectures. Slurries with solid loadings ranging from 40 to 50 vol% were prepared by mixing β-TCP powders with a photosensitive resin, dispersant, and methyl alcohol. Key processing parameters—including viscosity, exposure conditions, and debinding profile—were systematically optimized to achieve stable printing and defect-free sintering. Material characterization, mechanical evaluation of bulk specimens, and cytocompatibility assays were performed to assess processing feasibility. Specimens with 50 vol% solid loading exhibited the highest mechanical properties, with a Vickers hardness of 268 ± 8.72 HV, compressive strength of 55.27 ± 5.47 MPa, and flexural strength of 12.73 ± 0.96 MPa. All 3S-manufactured specimens demonstrated good cytocompatibility with MG-63 cells. Gyroid-structured scaffolds with 45 vol% solid loading exhibited a porosity of 72.45 ± 4.67%, as determined by micro-computed tomography, and supported cell attachment and proliferation. These findings establish the feasibility of fabricating high-solid-loading β-TCP gyroid-structured scaffolds via 3S technology and provide a foundation for future mechanical and biological investigations toward bone tissue engineering applications.