Bridging the gap: Optimized fabrication of robust titania nanostructures on complex implant geometries towards clinical translation.

Electrochemically anodized titanium surfaces with titania nanostructures (TNS; nanopores, nanotubes, etc.) have been widely applied as therapeutic bone/dental implant modifications. Despite the numerous advancements in the field of electrochemical anodization (EA), in terms of translation into the current implant market, research gaps in this domain include the lack of fabrication optimization, performed on a substrate of conventional implant surface/geometry, and inadequate mechanical stability. In the current study, we investigate the role of substrate pre-treatment on achieving desired nanotopographies for the purpose of reproducing optimized nanostructures on the complex geometry of commercial implant surfaces, as well as in-depth mechanical stability testing of these nano-engineered coatings. The results confirmed that: (a) substrate polishing/smoothening may be insignificant with respect to fabrication of well-ordered and high quality TNS on micro-rough implants with preserved underlying micro-roughness; (b) optimized outcomes can be successfully translated onto complex geometries characteristic of the current implant market, including dental implant abutments and screws (also applicable to a wider implant market including orthopaedics); (c) mechanical stability testing revealed improved modulus and hardness values as compared to conventional nanotubes/pores. We believe that such optimization advances the existing knowledge of titanium anodization and anodized implants towards integration into the current implant market and successful clinical translation.