Process parameter optimisation for manufacturing porous bioactive silicate glass microspheres via flame spheroidisation: The goldilocks effect

This study investigated the influence of flame spheroidisation process parameters for successfully manufacturing solid (dense) and highly porous microspheres from Food Drug Administration approved bioactive 45S5 glass with addition viscosity modifiers (i.e. 2 5 mol% borax V2O5), compared against processed phosphate (termed P40). Characterisation studies performed included thermal analysis (SDT), measurements using high temperature rotational viscometry hot stage microscopy, X-ray diffraction, scanning electron microscopy energy dispersive analysis. revealed that aside intrinsic material properties melt profiles), including starting particle size, cooling rate gas flow rates were important factors in achieving desired microsphere morphology. Considering above influential factors, a processing model has been proposed manufacture silicate glasses.