High virucidal potential of novel ceramic–metal composites fabricated via hybrid selective laser melting and spark plasma sintering routes

In this work, we combine selective laser melting (SLM) and spark plasma sintering (SPS) to fabricate new materials with high virucidal potential. Various bioactive disc-shaped ceramics, metal alloys, and composites were fabricated and tested against bacteriophage Phi6—a model system for RNA-enveloped viruses. We prepared silver-doped titanium dioxide (TiO2 + 2.5‒10% Ag), copper-doped titanium dioxide (TiO2 + 2.5‒10% Cu), Cu2NiSiCr, and Cu15Ni8Sn composite materials (metal lattices filled with ceramics). The virucidal tests of the ceramic and metal powders were performed in buffered suspensions, while the surfaces of the discs were tested by swabbing. The results show that the virus titer on the TiO2 + 10% Ag ceramic and CuNi2SiCr metal discs decreased by 4 logs after 15 min of exposure to the surfaces compared to the control ceramic and steel discs. We show that SLM 3D printed pre-alloyed CuNi2SiCr filled with bioactive TiO2 + 10% Ag nanopowders and sintered by the SPS process combines the simplicity of printing with the strength and virucidal properties of Ag and Cu materials. The proposed new virucidal materials were also used for the fabrication of prototype elevator buttons.