Fabrication of cancellous-bone-mimicking β-tricalcium phosphate bioceramic scaffolds with tunable architecture and mechanical strength by stereolithography 3D printing

It is highly challenging to fabricate bioceramic scaffolds mimicking architecture and mechanical strength of cancellous bone. Gyroid structure, which is based on triply periodic minimal surface, highly resembles the architecture of cancellous bone. Herein, β-tricalcium phosphate (β-TCP) bioceramic scaffolds with gyroid structure were fabricated by stereolithography (SLA) 3D printing. The SLA 3D printing ensured high precision of ceramic part. The porosity (51–87%), pore size (250 – 2400 µm), pore wall thickness (< 300 µm) and compressive strength (0.6 – 16.8 MPa) of gyroid bioceramic scaffolds were readily adjusted to match various sites of cancellous bone. The gyroid bioceramic scaffolds were more favorable for cell proliferation than the grid-like bioceramic scaffolds. The cancellous-bone-mimicking gyroid bioceramic scaffolds with tunable architecture and mechanical strength were expected to efficiently repair the target bone defects.     

The effect of pore morphology and agarose coating on mechanical properties of tricalcium phosphate scaffolds

Three-dimensional biocompatible porous structures can be fabricated using different methods. However, the biological and mechanical behaviors of scaffolds are the center of focus in bone tissue engineering. In this study, tricalcium phosphate scaffolds with similar porosity contents but different pore morphologies were fabricated using two different techniques, namely, the replica method and the pore-forming agent method. The samples fabricated using the pore-forming agent showed more than two times higher compressive and bending strengths and more than three times higher compressive moduli. Furthermore, a thin layer of agarose coating improved the compressive and bending strength of both types of ceramic scaffolds. Subsequently, the samples’ capability to guide biomineralization was evaluated by immersion into a simulated body fluid that developed Ca-P nano-platelets formation and enhanced the compressive strength. Finally, the tetrazolium-based colorimetric (MTT) assay was used to evaluate L929 cell viability and proliferation on all the samples and confirmed that cell behavior was not affected by pore morphology or agarose coating. In summary, samples produced by the use of the pore-forming agent showed higher potential to be applied as bone scaffolds in tissue engineering applications.     

Evaluation of direct light processing for the fabrication of bioactive ceramic scaffolds: Effect of pore/strut size on manufacturability and mechanical performance

Bioactive ceramic scaffolds for bone regeneration consisting of a three-dimensional mesh of interpenetrating struts with square section were fabricated via Digital Light Processing (DLP). The ability of the technique to manufacture 3D porous structures from β-tricalcium phosphate (β-TCP) powders with different dimensions of struts and pores was evaluated, identifying the possibilities and limitations of the manufacturing process. Small pore sizes were found to seriously complicate the elimination of excess slurry from the scaffold’s innermost pores. The effect of the strut/pore size on the mechanical performance of the scaffolds under compressive stresses was also evaluated, but no significant influence was found. Under compressive stresses, the structures resulted weaker when tested perpendicularly to the printing plane due to interlayer shear failure. Interlayer superficial grooves are proposed as potential failure-controlling defects, which could also explain the lack of a Weibull size effect on the mechanical strength of the fabricated DLP scaffolds.     

Novel fabrication of hierarchically porous hydroxyapatite scaffolds with refined porosity and suitable strength

Based on extrusion deposition and foaming technique, a novel method for biological hydroxyapatite (HA) scaffolds was introduced in this paper. The scaffolds were primarily characterised by interconnected and hierarchically porous structures with high porosity, adjustable distribution of pore sizes, as well as considerable mechanical strength. In order to confirm that fine control of bulk porosity and mechanical strength was possible and feasible, further analysis of obtained scaffolds was carried out by field emission scanning electron microscope (FESEM), compressive test and calculation of volumetric shrinkage; in particular, the additional porosity resulting from the introduction of pore former was evaluated. The results indicated that this method can have a great potential to construct HA scaffolds of suitable quality for spongy bone in bone tissue engineering.     

Improvement of mechanical properties of macroporous β-tricalcium phosphate bioceramic scaffolds with uniform and interconnected pore structures

The biocompatible and degradable macroporous bioceramic scaffolds with high mechanical properties and interconnected porous structures play an important role in hard tissue regeneration and bone tissue engineering applications. In this study, the improvement of mechanical properties of macroporous β-tricalcium phosphate [β-Ca₃(PO₄)₂, β-TCP] bioceramic scaffolds with uniform macropore size and interconnected pores were fabricated by impregnation of the synthesized β-TCP nano-powder slurry into polymeric frames. The microstructures, mechanical properties and in vitro degradation of the fabricated samples were investigated. For a comparison, β-TCP scaffolds were also fabricated from commercial micro-size powders under the same conditions. The resultant scaffolds showed porosities ∼65% with uniform macropore size ranging from 400 to 550 μm and interconnected pore size ∼100 μm. The compressive strength of the samples fabricated from nano-size powders reached 10.87 MPa, which was almost twice as high as those fabricated from commercial micro-size powders, and was comparable to the high-end value (2–10 MPa) of human cancellous bone. Furthermore, the degradation of the β-TCP bioceramics fabricated from nano-size powders was apparently lower than those fabricated from commercial micro-size powders, suggesting the possible control of the degradation of the scaffolds by regulating initial powder size. Regarding the excellent mechanical properties and porous structures, the obtained macroporous β-TCP bioceramic scaffolds can be used in hard tissue regeneration and bone tissue engineering applications.     

Improving mechanical properties of porous calcium phosphate scaffolds by constructing elongated gyroid structures using digital light processing

The present study reports the manufacturing of a novel type of porous calcium phosphate scaffolds with elongated gyroid structures using digital light processing (DLP), in order to offer significantly enhanced mechanical properties. In particular, solid camphor was employed as the diluent, in order to offer sufficiently low viscosity at high solid loading for conventional layer-by-layer DLP process. Four types of porous CaP scaffolds with different percent elongation (%EL = 0, 20, 40, and 60) were manufactured, and their porous structures and mechanical properties were characterized. All porous CaP scaffolds showed that CaP walls were elongated along the z-direction, while the degree of pore elongation increased with an increase in the designed %EL. Owing to the use of controlled processing parameters, such as layer thickness and exposure time for layer-by-layer photocuring process, and carefully designed debinding process, the photocured layers could be completely bonded together with high densification after sintering at 1,200 °C for 3 h. Such elongation of a gyroid structure offered significantly enhanced mechanical properties ? compressive strengths of 4.33 ± 0.26 MPa and 11.51 ± 1.75 MPa were obtained for the porous CaP scaffold with the %EL of 0 and 60, respectively.     

Characterization of 3D elastic porous polydimethylsiloxane (PDMS) cell scaffolds fabricated by VARTM and particle leaching

In this study, elastic porous polydimethylsiloxane (PDMS) cell scaffolds were fabricated by vacuum‐assisted resin transfer moulding (VARTM) and particle leaching technologies. To control the porous morphology and porosity, different processing parameters, such as compression load, compression time, and NaCl particle size for preparing NaCl preform, were studied. The porous structures of PDMS cell scaffolds were characterized by scanning electron microscopy (SEM). The properties of PDMS cell scaffolds, including porosity, water absorption, interconnectivity, compression modulus, and compression strength were also investigated. The results showed that after the porogen–NaCl particles had been leached, the remaining pores had the sizes of 150–300, 300–450, and 450–600 μm, which matched the sizes of the NaCl particles. The interconnectivity of PDMS cell scaffolds increases with an increase in the size of NaCl particles. It was also found that the smaller the size of the NaCl particles, the higher the porosity and water absorption of PDMS cell scaffolds. The content of residual NaCl in PDMS/NaCl scaffolds reduces under ultrasonic treatment. In addition, PDMS scaffolds with a pore size of 300–450 μm have better mechanical properties compared to those with pore sizes of 150–300 and 450–600 μm. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 42909.     

Effects of microwave sintering on the properties of porous hydroxyapatite scaffolds

Microwave sintering was used to process porous hydroxyapatite scaffolds fabricated by the extrusion deposition technique. The effects of microwave sintering on the microstructure, phase composition, degradation, compressive strength and biological properties of the scaffolds were investigated. After rapid sintering, scaffolds with controlled structure, high densification and fine grains were obtained. A significant increase in mechanical strength was observed relative to conventional sintering. The scaffolds (55–60% porosity) microwave sintered at 1200 °C for 30 min exhibited the highest average compressive strength (45.57 MPa). The degradation was determined by immersing the scaffolds in physiological saline and monitoring the Ca²⁺concentration. The results indicated that the microwave-sintered scaffolds possessed higher solubility than conventionally sintered scaffolds, as it released more Ca²⁺ at the same temperature. Furthermore, an in vitro MC3T3-E1 cell culturing study showed significant cell adhesion, distribution, and proliferation in the microwave-sintered scaffolds. These results confirm that microwave sintering has a positive effect on the properties of porous hydroxyapatite scaffolds for bone tissue engineering applications.     

Compressive strength of β-TCP scaffolds fabricated via lithography-based manufacturing for bone tissue engineering

Bone is a vital organ that is responsible for the support and movement of body as well as the storage and transportation of cells and nutrients. Disease, along with traumatic events, can leave regions of bone with large voids and/or defects. Related surgical procedures, such as allografts, autografts, and arthroplasty, are reported to amount to roughly €9.6bn annually, emphasising the need for bone repair/replacement globally. Tricalcium phosphate (TCP) is a bioactive ceramic that has been identified as a suitable material for bone tissue engineering applications due to its excellent bioresorbability and overall biocompatibility. Through lithography-based ceramic manufacturing (LCM), β -TCP scaffolds were fabricated across nine different designs in this work. Pore size, unit cell size, and unit cell geometry were altered to vary the porosity of these scaffolds. Following fabrication, the material composition, topography, macrostructure, and microstructure of the β-TCP scaffolds were characterised. The effects of porosity and unit cell geometry on the compressive strengths of β -TCP scaffolds were analysed in detail. Compressive strengths of the scaffolds were measured between 1.4 ± 0.5 MPa and 67.6 ± 13.3 MPa across a porosity range of 5.58 ± 0.09% to 59.36 ± 0.18%. The strength of these scaffolds was considerably lower than that of the compressive strength of cortical bone (100–200 MPa), but mimic the compressive strength of cancellous bone well (0.1–16 MPa). While scaffolds of β-TCP alone may not be suitable for load-bearing applications, they demonstrate enough mechanical stability for bone regeneration/tissue engineering applications. They hold more potential in the regeneration of small bone defects/voids or in composite materials.     

Biphasic calcium phosphate scaffolds fabricated by direct write assembly: Mechanical,anti-microbial and osteoblastic properties

The present work reports on the fabrication of 3-D porous calcium phosphate scaffolds by robocasting from biphasic (HA/β-TCP ≈ 1.5) powders, undoped and co-doped with Sr and Ag. Scaffolds with different pore sizes and rod diameter of 410 μm were fabricated and sintered at 1100 °C. The size and morphology of the powder particles, and the concentrations of the processing additives, were shown to play major roles in the robocasting process. For all pore sizes tested, the compressive strength of scaffolds was comparable to or even higher than that of cancellous bone, and mechanical data could be systematically correlated with the porosity fraction. Co-doping the starting powders with Sr and Ag enhanced the mechanical strength of scaffolds, conferred good antimicrobial activity against Staphylococcus aureus and Escherichia coli, and did not induce any cytotoxic effects on human MG-63 cells. Furthermore, the co-doped powder was more effective in inducing pre-osteoblastic proliferation.     

Effect of infill pattern on the mechanical properties of polydopamine-coated polylactic acid orthopedic bone plates developed by fused filament fabrication

Distal fractures are the most commonly experienced type of fractures that require fixation of bone plates for healing of fractured bones. Poly Lactic Acid (PLA)-based bone plates are porous and light in weight. However, they lack mechanical properties that limit their application in biomedical field. Polydopamine coating has been witnessed to undergo covalent interactions, enhancing the mechanical properties of the substrate. The present study is based on the fabrication of PLA-based bone plates using Fused Filament Fabrication with varying infill patterns. The infill patterns in the study include octet, cubic, grid, concentric, lines, and gyroid. Thereafter, polydopamine coating was deposited on these bone plates using direct immersion coating method. In the study, the effect of infill pattern on coating deposition and modification of mechanical properties has been studied. The microscopic images of fractured bone plates were captured. It was concluded that polydopamine coating was successful in improving mechanical properties for all infill patterns. The findings suggested that a concentric pattern should be used for applications that require both high mechanical strength and maximum elongation at break because elongation at break is higher for concentric patterns than gyroid patterns. Also, for applications requiring only high mechanical strength, a gyroid pattern should be used.     

Rapid preparation of novel MgNH4PO4·H2O porous scaffolds via 3D-printing combined with a hydrothermal-process-assisted post treatment

Novel dittmarite (MgNH₄PO₄·H₂O) 3D porous scaffolds were firstly fabricated via 3D-printing combined with a hydrothermal-process-assisted post treatment. Powder X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) were used to characterize the phases, morphologies, and element compositions of the 3D porous structures. The hydrothermal process played the key role in the formation of dittmarite phase. The porosity, compressive strength, and in vitro degradation of the dittmarite scaffolds were studied in detail. In addition, the cytotoxicity on MC3T3-E1 osteoblast cells and cell adhesion were evaluated and the results showed that the dittmarite porous scaffold possessed superior cytocompatibility and could support MC3T3-E1 cellular attachment. The research indicated that dittmarite porous scaffolds had a wide application prospect in bone tissue repair fields.     

Nano‐Hydroxyapatite Improves the Properties of β‐tricalcium Phosphate Bone Scaffolds

β‐Tricalcium phosphates have been widely used as biomaterials for bone substitutes; however, the poor mechanical properties limit the application in bearing loading bones. In this study, nano‐hydroxyapatite has been introduced to improve the mechanical properties for porous bioceramic scaffolds. Nanocomposites containing 0–10 wt% needle‐like nano‐hydroxyapatite were prepared for investigation. It has been found that needle‐like nano‐hydroxyapatite improves the toughness, hardness, and compressive strength of the porous β‐tricalcium phosphates scaffolds, as well as the microstructure properties. The study provides a reference for the development of safe, excellent bone scaffolds for bone tissue engineering.     

Fabrication and properties of 3D printed zirconia scaffold coated with calcium silicate/hydroxyapatite

The scaffold of bone repair needs a variety of material combinations to meet its intended performance; a typical single material such as zirconia has excellent mechanical properties, while hydroxyapatite and calcium silicate are bioactive materials with different degradation rates. In this paper, porous zirconia scaffolds were fabricated using 3D printing technology. The surface of the scaffold was coated by dipping with different contents of calcium silicate and hydroxyapatite to improve the biological activity and mechanical properties. Mechanical tests show that the coating material can effectively fill the pores of the porous scaffold, increasing its compressive strength by an average of 55%. The simulated body fluid (SBF) test showed that the higher calcium silicate in the coating increased the degradation rate. Cell experiments showed that the coated scaffolds exhibited good cytocompatibility and were beneficial to the proliferation and differentiation of cells. In conclusion, coated scaffolds have potential applications in the field of bone repair.     

Improvement of mechanical properties and in vitro bioactivity of freeze-dried gelatin/chitosan scaffolds by functionalized carbon nanotubes

Functionalized multiwall carbon nanotubes (f-MWCNTs) were used to reinforce the freeze-dried gelatin (G)/chitosan (Ch) scaffolds for bone graft substitution. Two types of G/Ch scaffolds at a ratio of 2:1 and 3:1 by weight incorporated with 0.025, 0.05, or 0.1 and 0.2 or 0.4?wt% f-MWCNT, respectively, were prepared by freeze drying, and their structure, morphology, and physicochemical and compressive mechanical properties were evaluated. The scaffolds exhibited porous structure with pore size of 80–300 and 120–140?µm for the reinforced scaffolds of G/Ch 2:1 and 3:1, respectively, and porosity 90–93% which slightly decreased with an increase in f-MWCNTs content for both types. Incorporation of f-MWCNTs led to 11- and 9.6-fold increase in modulus, with respect to their pure biopolymer blend scaffolds at a level of 0.05?wt% for G/Ch 2:1 and 0.2?wt% for G/Ch 3:1, respectively. The higher content of f-MWCNTs resulted in loss of mechanical properties due to agglomeration. The highest value of compressive strength and modulus was obtained for G/Ch 2:1 with 0.05?wt% f-MWCNT as 411?kPa and 18.7?MPa, respectively. Improvement of in vitro bioactivity as a result of f-MWCNTs incorporation was proved by formation of a bone-like apatite layer on the surface of scaffolds upon immersion in simulated body fluid. The findings indicate that the f-MWCNT-reinforced gelatin/chitosan scaffolds may be a suitable candidate for bone tissue engineering.     

Gelatin-layered and multi-sized porous β-tricalcium phosphate for tissue engineering scaffold

The multi-sized porous β-tricalcium phosphate scaffolds were fabricated by freeze drying followed by slurry coating using a multi-sized porous sponge as a template. Then, gelatin was dip coated on the multi-sized porous β-tricalcium phosphate scaffolds under vacuum. The mechanical and biological properties of the fabricated scaffolds were evaluated and compared to the uniformly sized porous scaffolds and scaffolds that were not coated by gelatin. The compressive strength was tested by a universal testing machine, and the cell viability and differentiation behavior were measured using a cell counting kit and alkaline phosphatase activity using the MC3T3-E1 cells. In comparison, the gelatin-coated multi-sized porous β-tricalcium phosphate scaffold showed enhanced compressive strength. After 14 days, the multi-sized pores were shown to affect cell differentiation, and gelatin coatings were shown to affect the cell viability and differentiation. The results of this study demonstrated that the multi-sized porous β-tricalcium phosphate scaffold coated by gelatin enhanced the mechanical and biological strengths.     

Collagen‐based scaffolds reinforced by chitosan fibres for bone tissue engineering

In this paper, porous bone scaffolds reinforced with chitosan fibres were prepared. The porosity and pore size of the reinforced scaffolds were both satisfactory. The reinforced scaffolds resembled natural bone in both components and crystal size. Only if the length of the fibres was no shorter than the critical length, could the fibres reinforce the material. We have proposed an empirical formula to calculate the critical length of the fibres for the porous materials and determined the modifying factor (F_l) for the porous bone scaffold investigated in this work. Along with the increase of the fibres' volume content, the compressive strength of the scaffold also increased. We have proposed a further empirical formula for calculating the compressive strength of the porous reinforced materials and determined the modifying factor (F_σ) for the porous reinforced bone scaffold examined in these studies. Along with the degradation in vitro, the decrease in strength of the reinforced scaffold was less than that of the unreinforced scaffold. The growth rate of osteoblast cells on the reinforced scaffold was higher than that on the unreinforced scaffold. These results suggest that the reinforced scaffold may be a promising candidate matrix for repairing large bone defects. Copyright © 2005 Society of Chemical Industry     

Fabrication and characterization of porous β-tricalcium phosphate scaffolds coated with alginate

All porous materials have a common limitation which is lack of strength due to the porosity. In this study, two different methods have been used to produce porous β-tricalcium phosphate (β-TCP) scaffolds: liquid-nitrogen freeze casting and a combination of the direct-foaming and sacrificial-template methods. Among these two methods, porous β-TCP scaffolds with acceptable pore size and compressive strength and defined pore-channel interconnectivity were successfully fabricated by the combined direct-foaming and sacrificial-template method. The average pore size of the scaffolds was in the range of 100–150 µm and the porosity was around 70%. Coating with 4 wt% alginate on porous β-TCP scaffolds led to higher compressive strength and low porosity. In order to make a chemical link between the β-TCP scaffolds and the alginate coating, silane coupling agent was used. Treated β-TCP scaffold showed improvements in compressive strength of up to 38% compared to the pure β-TCP scaffold and 11% compared to coated β-TCP scaffold.     

Effect of particle size and freezing conditions on freeze-casted scaffold

Freeze casting is one of the emerging and novel manufacturing routes to fabricate porous scaffolds for various applications including orthopedic implants, drug delivery, energy storing devices etc. Thus, it becomes important to understand this process in a deeper sense. Present work was focused to study the effect/influence of basic parameters, particle sizes, and freezing conditions on the mechanical properties and microstructures of porous scaffold fabricated by freeze casting. β-tricalcium phosphate (β-TCP) and hydroxyapatite (HAp) powder with particle sizes of 10?μm and 20?nm were used. Prepared slurries were freeze casted at constant freezing temperature (5?°C) and constant freezing rate (1.86?°C/min) to study the effect of freezing conditions on mechanical and microstructural properties of the porous scaffold. It was observed that porous scaffold fabricated by nanoparticles has given better porosity (63.22–76.16%), than scaffold fabricated by microparticles (13–43.05%) at given solid loading of both freezing conditions. Although, the range of pore size of the scaffold fabricated by nanoparticles (CFR: 2.60–0.84?μm; CFT: 1.66–0.46?μm) was lower than that of scaffold fabricated by microparticles (CFR: 9.45–4.83?μm; CFT: 4.72–2.84?μm). The compressive strength of scaffolds prepared by nanoparticles was in the range of trabecular bone. Moreover, the results of present work will pave the way for the fabrication of porous scaffold with desired pore size and porosity for various implants, energy, and drug delivery applications.     

壳聚糖/生物活性玻璃多孔复合支架的制备及界面增强作用

采用卵磷脂作为表面活性剂对溶胶-凝胶生物玻璃进行表面改性,并采用冷冻干燥法制备用于骨和软骨组织工程的壳聚糖/生物活性玻璃复合多孔支架(chitosan/bioglass porous composite scaffolds,CS/BGS),观察CS/BGS的显微形貌并测定抗压强度,探讨生物玻璃的表面改性对CS/BGS显微结构及力学强度的影响。研究表明:采用冷冻干燥法可以制备具有一定强度的三维连通的CS/BGS,且孔隙率达到90%以上。通过对生物玻璃表面改性可以在一定程度上提高CS/BGS的抗压强度。