Fabrication of porous scaffolds with a controllable microstructure and mechanical properties by porogen fusion technique

Macroporous scaffolds with controllable pore structure and mechanical properties were fabricated by a porogen fusion technique. Biodegradable material poly (d, l-lactide) (PDLLA) was used as the scaffold matrix. The effects of porogen size, PDLLA concentration and hydroxyapatite (HA) content on the scaffold morphology, porosity and mechanical properties were investigated. High porosity (90% and above) and highly interconnected structures were easily obtained and the pore size could be adjusted by varying the porogen size. With the increasing porogen size and PDLLA concentration, the porosity of scaffolds decreases, while its mechanical properties increase. The introduction of HA greatly increases the impact on pore structure, mechanical properties and water absorption ability of scaffolds, while it has comparatively little influence on its porosity under low HA contents. These results show that by adjusting processing parameters, scaffolds could afford a controllable pore size, exhibit suitable pore structure and high porosity, as well as good mechanical properties, and may serve as an excellent substrate for bone tissue engineering.     

Fabrication of Hydroxyapatite/Ethylene-Vinyl Acetate/Polyamide 66 Composite Scaffolds by the Injection-Molding Method

This research investigated the injection-molding techniques to produce hydroxyapatite (HA)/ethylene-vinyl acetate (EVA)/polyamide 66 (PA66) composite scaffolds. The effects of HA, EVA, azodicarbonamide (AC) content and shot size on the mechanical properties, pore morphology, porosity and crystallization behavior of the composite scaffolds were analyzed by XRD, DSC, SEM and mechanical test. The compressive modulus and strength of the HA/EVA/PA66 scaffolds with a pore size of 200–600 µm are close to the cancellous bone. Compared with common methods to fabricate scaffolds, this process makes the fabrication of composite scaffolds come true in a rapid and convenient manner.     

A novel fabrication procedure for producing high strength hydroxyapatite ceramic scaffolds with high porosity

Hydroxyapatite (HA) scaffolds were fabricated using the space holder method with a pressureless sintering process in a systematically developed manner at different fabrication stages to increase the strength of the scaffold at high porosity. Polyvinyl alcohol (PVA) and Polymethyl methacrylate (PMMA) were used as binders and space holder agents, respectively. The physical properties of the HA scaffolds were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), linear shrinkage test, and porosity measurements. The mechanical properties of the HA scaffolds were analyzed using compressive strength measurements. The results revealed that the HA scaffold met the expected quality requirements with a compressive strength of 2.2 MPa at a porosity of 65.6% with pore sizes distributed in the range of 126–385 μm. The shrinkage of the scaffold diameter occurred by 20.27%, this diameter shrinkage predominantly to the shrinkage of the HA scaffold caused by sintering. Besides, suspect that a higher PMMA concentration causes pore size shrinkage upon sintering. The formation of pore interconnections was evidenced by SEM observations and the ‘translucent light method’ developed in this study. The results of the scaffold phase test using XRD showed that the final scaffold consisted only of the HA phase, as the PVA and PMMA phases burned out during the sintering process.     

Injection‐molded porous hydroxyapatite/polyamide‐66 scaffold for bone repair and investigations on the experimental conditions

Hydroxyapatite/polyamide‐66 (HA/PA66) composite scaffolds were prepared using injection‐molding technique and also analyzed by means of scanning electron microscopy, X‐ray diffraction, differential scanning calorimetry, Fourier transform infrared spectroscopy, and mechanical testing. Compared with common methods to fabricate scaffolds, this process can fabricate composite scaffolds in a rapid and convenient manner by adjusting the experimental conditions of foaming agent and shot size. The interactions between PA66 and HA particles affect the crystallization behavior of PA66 and the pore structure of scaffolds. HA particles can increase the stiffness of composite scaffolds accompanied by the reduction of impact strength, pore size and porosity. The obtained 40 wt% HA/PA66 composite scaffolds with a pore size ranging from 100–500 μm and a porosity more than 65% can simultaneously meet the requirements of porous structure and mechanical performance. POLYM. ENG. SCI., 54:1003–1012, 2014. © 2013 Society of Plastics Engineers     

Modification of hydroxyapatite (HA) powder by carboxymethyl chitosan (CMCS) for 3D printing bioceramic bone scaffolds

The poor mechanical properties of 3D printed HA bone scaffold is always a challenge in tissue engineering, to address this issue, carboxymethyl chitosan (CMCS) was proposed to modify HA bone scaffolds by a physical blending method in this research. A series of HA and HA/CMCS composite ceramic scaffolds were printed by using piezoelectric inkjet 3D printing technology, and their properties were investigated in terms of forming quality, structural morphology, mechanical properties, degradability, cytotoxicity, and cell adhesion growth. The results of forming quality and structural morphology show that with the increase of CMCS content, the forming quality of the samples deteriorated, the pore size and porosity increased. However, when the content of CMCS reached 5 wt%, obvious cracks appeared on the surface of the sample, and the forming quality was relatively poor. The mechanical testing results indicated the toughness of composites could be enhanced by incorporating CMCS into HA, which was attributed to the higher strength connections of the CMCS polymer network between HA particles and the stronger interaction between HA and CMCS molecules. FTIR spectra further revealed the strong hydrogen bonding interaction between CMCS and HA. Moreover, the degradation rate and mineralization ability of the sample increased with the content of CMCS, but the compressive strength during degradation increased with the CMCS content, indicating that incorporating CMCS into HA cannot only improve the mechanical property and biological activity of the scaffold but also makes up the defect of slow degradation of pure HA scaffold. Finally, the cytotoxicity, cell adhesion, and cell proliferation tests show that HA and HA/CMCS composite samples had good cytocompatibility, HA/CMCS sample with 3 wt% CMCS possessed the best bioactivity. In summary, HA/CMCS composite powder with 3 wt% CMCS content is the optimal matrix material for 3D printing bone scaffolds.     

Morphology,wettability, and mechanical properties of polycaprolactone/hydroxyapatite composite scaffolds with interconnected pore structures fabricated by a mini‐deposition system

A new mini‐deposition system (MDS) was developed to fabricate scaffolds with interconnected pore structures and anatomical geometry for bone tissue engineering. Polycaprolactone/hydroxyapatite (PCL/HA) composites with varying hydroxyapatite (HA) content were adopted to manufacture scaffolds by using MDS with a porosity of 54.6%, a pore size of 716 μm in the x‐y plane, and 116 μm in the z direction. The water uptake ratio and compressive modulus of PCL/HA composite scaffold increase from 8 to 39% and from 26.5 to 49.8 MPa, respectively, as the HA content increases from 0 to 40%. PCL/HA composite scaffolds have better wettability and mechanical properties than pure PCL scaffold. A PCL/HA composite scaffold for mandible bone repair was successfully fabricated with both interconnected pore structures and anatomical shape to demonstrate the versatility of MDS. POLYM. ENG. SCI., 2012. © 2012 Society of Plastics Engineers     

Biocompatibility and strengthening of porous hydroxyapatite scaffolds using poly(l-lactic acid) coating

Hydroxyapatite (HA) is a well-known biocompatible bone substitute. Porous HA is more resorbable and osteoconductive compared with non-porous HA, and has been studied both experimentally and clinically. However, the mechanical strength of porous HA scaffolds is known to be weak. In this study, we developed a porous HA scaffold coated with a synthetic biodegradable polymer, poly(l-lactic acid) (PLLA), to strengthen the scaffold. PLLA-coated HA pellets were used to investigate the in vitro proliferation and alkaline phosphatase (ALP) activity of osteoblasts. PLLA-coated porous HA scaffolds were observed using scanning electron microscopy to investigate surface characteristics, porosity, and mechanical strength. PLLA coating concentration varied from 2 to 10 wt%. Osteoblast proliferation was higher in HA samples coated with PLLA compared with non-coated. ALP activity was highest on 8 wt% PLLA-coating after 3 days and on 4 wt% and 6 wt% PLLA after 9 and 12 days. Porous HA scaffolds with higher concentrations of PLLA were found to have a smoother, flatter surface. This enhanced proliferation and attachment of osteoblasts onto the porous HA scaffold. PLLA solution at a concentration of 10 wt% decreased scaffold porosity to half that of HA scaffolds with no PLLA coating. Scaffold mechanical strength was increased two-fold with a PLLA concentration of 2 wt%. Based on in vitro experimentation, it can be concluded that PLLA-coating on porous HA scaffolds enhances both the biocompatibility and the mechanical strength.     

可注射nHA/PU复合多孔骨修复支架制备及表征

兼具良好孔隙率和原位任意塑形固化的可注射复合多孔骨修复材料在临床不规则骨缺损的治疗方面显示出巨大的优势。本研究通过优化双组分设计,以水为发泡剂制备可注射纳米羟基磷灰石/聚氨酯（nHA/PU）复合多孔支架。利用扫描电子显微镜（SEM）、傅里叶变换红外光谱（FTIR）、X射线衍射（XRD）、力学测试及Gillmore针测试等手段对制备的支架进行结构形貌、化学组成、力学性能和固化时间表征。结果表明,本研究制备的可注射nHA/PU复合多孔支架孔隙率高、孔隙贯通性好,孔径分布在100~700μm,适宜细胞和组织向孔内生长;添加20% nHA显著提高了PU支架的力学强度,但降低了支架的孔隙率;可注射支架在8h固化,适宜临床操作。本研究制备的可注射nHA/PU复合多孔支架在不规则骨缺损修复领域具有较大的应用潜力。     

Two-step modification process to improve mechanical properties and bioactivity of hydroxyfluorapatite scaffolds

Porous ceramic scaffolds are synthetic implants, which support cell migration and establish sufficient extracellular matrix (ECM) and cell-cell interactions to heal bone defects. Hydroxyapatite (HA) scaffolds is one of the most suitable synthetic scaffolds for hard tissue replacement due to their bioactivity, biocompatibility and biomimetic features. However, the major disadvantages of HA is poor mechanical properties as well as low degradability rate and apatite formation ability. In this study, we developed a new method to improve the bioactivity, biodegradability and mechanical properties of natural hydroxyfluorapatite (HFA) by applying two-step coating process including ceramic and polymer coats. The structure, morphology and bioactivity potential of the modified and unmodified nanocomposite scaffolds were evaluated using transmission electron microscopy (TEM), scanning electron microscopy (SEM), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and energy dispersive spectroscopy (EDS). The scaffold with optimized mechanical properties was HFA-30?wt%HT (HT stands for hardystonite) with a total porosity and pore size of 89?±?1 and 900–1000?µm, respectively. The compressive modulus and strength of HFA (porosity ~ 93?±?1) were improved from 108.81?±?11.12–251.45?±?12.2?MPa and 0.46?±?0.1–1.7?±?0.3?MPa in HFA-30?wt%HT sample, respectively. After applying poly(ε-caprolactone fumarate) (PCLF) polymer coating, the compressive strength and modules increased to 2.8?±?0.15 and 426.1?±?15.14?MPa, respectively. The apatite formation ability of scaffolds was investigated using simulated body fluid (SBF). The results showed that applying the hardystonite coating improve the apatite formation ability; however, the release of ions increased the pH. Whereas, modified scaffolds with PCLF could control the release of ions and improve the apatite formation ability as well.     

Glutaraldehyde‐crosslinked chitosan/hydroxyapatite bone repair scaffold and its application as drug carrier for icariin

Chitosan/hydroxyapatite (CS/HA) bone repair scaffolds crosslinked by glutaraldehyde (GA) were prepared. Characterization of morphology, structure, mechanical property, and porosity of scaffolds were evaluated. The influences of CS viscosity, HA content, and crosslinking degree on properties of scaffolds were discussed. SEM images showed that CS/HA scaffolds were porous with short rod‐like HA particles dispersing evenly in CS substrate. When [η]_CS = 5.75 × 10^?4, HA content = 65%, and crosslinking degree = 10%, the resulting CS/HA scaffolds had a flexural strength of 20 MPa and porosity of 60%, which could meet the requirements of bone repair materials. The scaffolds were used as drug carriers for icariin, and the impacts of loading time and crosslinking degree of scaffolds on drug‐loading dose were discussed. The suitable loading time was 24 h and it would be better to keep crosslinking degree no more than 10%. The drug release behavior demonstrated that the icariin‐loading CS/HA scaffolds could achieve basic drug sustained release effect. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 130: 1539–1547, 2013     

Three-Dimensional Microstructural Characterization of Porous Hydroxyapatite Using Confocal Laser Scanning Microscopy

The characterization of porosity is crucial in the development and commercialization of ceramic bone replacement technology, since the pore size and interconnectivity play a central role in both biological function (bone ingrowth and nutrient flow) as well as mechanical properties of bone scaffolds. The ability of confocal laser scanning microscopy (CLSM) to image three-dimensional (3-D) structures with large vertical depths (∼2 mm) and fine vertical resolution (∼1 μm) is utilized in this article to characterize the 3-D microstructures of hydroxyapatite (HA) bone scaffold specimens with porosity ranging from roughly 60–70 vol%. Various CLSM techniques are applied to image and interpret the HA pore structure, including Z -series stacking, topographic profiling, and Phi- Z scanning and contour mapping.     

改进粒子沥滤法制备PLA/HA支架及其性能

采用溶剂浇铸/真空挥发/粒子沥滤法(SC/VV/PL)制备了聚乳酸(PLA)和PLA/羟基磷灰石(HA)多孔支架,研究了支架的结构、力学性能、亲水性能等.从扫描电镜结果可以看出支架孔径与所用的致孔剂氯化钠(NaCl)的粒径符合良好,PLA和PLA/HA支架的孔隙率均大于79%,压缩模量、接触角、吸水率的测试结果表明,HA的加入显著改善了PLA支架的力学性能和亲水性能.     

Fabrication of three-dimensional interconnected porous blocks composed of robust carbonate apatite frameworks

In scaffolds used for bone regeneration, osteogenic ability increases and mechanical strength decreases with increasing porosity. To ensure both mechanical strength and osteogenesis, an optimal pore architecture is necessary. Porous glass has high porosity and high mechanical strength, as it is framed with a rigid interconnected silica network and void interspaces in the silica network. In this context, based on the porous structure of glass, we fabricated porous blocks composed of carbonate apatite (CO₃Ap), which is the major component of human bone mineral, with both high mechanical strength and high porosity. To fabricate the CO₃Ap blocks, first, calcite-polymethyl methacrylate (PMMA) mixture granules were prepared. Next, the calcite-PMMA granules were allowed to join together in the mold by fusing PMMA, resulting in the formation of porous blocks composed of interconnected calcite-PMMA granules. Next, PMMA was thermally removed and the resultant interconnected calcite granules were partially sintered. Finally, the composition of the interconnected granules was converted from calcite to CO₃Ap in a dissolution-precipitation reaction. Consequently, CO₃Ap blocks with a continuous pore architecture were successfully fabricated. The porosity and diametral tensile strength were controllable within the range of 60‒70% and 1.0‒1.5 MPa, respectively, by filling the space between the calcite-PMMA granules. As these values are suitable for clinical use, the porous CO₃Ap blocks have potential applications as scaffolds for bone regeneration.     

Fabrication and characterization of honeycomb β-tricalcium phosphate scaffolds through an extrusion technique

In this study, for the first time honeycomb β-tricalcium phosphate (β-TCP) scaffolds were fabricated through an extrusion technique. The physicochemical properties and cell behaviors of the honeycomb β-TCP scaffolds were investigated. The results showed that scaffolds were characterized by ordered channel-like macropores and unidirectional interconnection. The pore structure and mechanical strength could be tailored by changing the parameters of extrusion molds. The pore size of scaffolds was in the range of 400–800 µm approximately, while their compressive strength parallel to the pore direction and porosity ranged from 14 to 20 MPa and 60–70%, respectively. The in vitro cell behavior demonstrated that cells could well attach on the surfaces and grow into the inner channel-like pores of thescaffolds; the scaffolds with higher porosity showed better cell proliferation but poorer cell differentiation. The honeycomb scaffolds fabricated by extrusion technique are potential candidate for bone tissue engineering.     

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.     

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.     

Comparison of osteogenesis in poly(L-lactic acid)-coated and non-coated porous hydroxyapatite scaffolds

To improve the biocompatibility and mechanical strength of porous hydroxyapatite (HA) scaffolds that have high osteoconduction, we coated them with 1, 5, or 10 wt% poly(L-lactic acid) (PLLA). In the 5 and 10 wt% PLLA-coated groups, osteoblast proliferation rates were higher than those in non-coated and 1 wt% PLLA-coated groups. The alkaline phosphatase (ALP) activity was highest in the 5 wt% PLLA-coated group. In addition, the porosity was highest in the non-coated HA group (82 %), whereas it was 72, and 41 % in the 5, and 10 wt% PLLA-coated groups, respectively. Scaffold strength increased in proportion to the concentration of PLLA coating. Overall, the 5 wt% PLLA scaffold had best characteristics when considering osteoblast proliferation, ALP activity, porosity, and compressive strength. We next tested this scaffold in an in vivo alveolar defect rabbit model. Multi-detector row computed tomography showed that non-coated and 5 wt% PLLA-coated HA groups had a similar high density. Adequate osteogenesis was observed by histological analysis in the non-coated HA and 5 wt% PLLA-coated HA groups. In addition, sufficient mineralization was observed in the coated scaffolds by X-ray fluorescence spectroscopy without significant adverse effects. Therefore, based on our findings, a PLLA-coated porous HA scaffold may be a suitable bone substitute for the correction of bone defects.     

Preparation and characterisation of HA/TCP biphasic porous ceramic scaffolds with pore-oriented structure

Porous hydroxyapatite/tricalcium phosphate (HA/TCP) ceramic scaffolds with a uniform unidirectional pore structure were successfully fabricated by an ice-templating method by using Ca-deficient HA whiskers and phosphate bioglass. HA whiskers showed good dispersibility in the slurry and favoured the formation of interconnected pores in the scaffolds. Addition of bioglass powders enhanced the material sintering process and the phase transformation of Ca-deficient HA to β-TCP. Calcium-phosphate-based scaffolds with a composition from HA to an HA/β-TCP complex could be obtained by controlling the freezing moulding system and slurry composition. The fabricated scaffolds had a porosity of 75–85%, compressive strength of 0.5–1.0 MPa, and a pore size range of 130–200 µm.     

Characterisation of Bioglass based foams developed via replication of natural marine sponges

A comparative characterisation of Bioglass based scaffolds for bone tissue engineering applications developed via a replication technique of natural marine sponges as sacrificial template is presented, focusing on their architecture and mechanical properties. The use of these sponges presents several advantages, including the possibility of attaining higher mechanical properties than those scaffolds made by foam replica method (up to 4?MPa) due to a decrease in porosity (68–76%) without affecting the pore interconnectivity (higher than 99%). The obtained pore structure possesses not only pores with a diameter in the range 150–500?μm, necessary to induce bone ingrowth, but also pores in the range of 0–200?μm, which are requested for complete integration of the scaffold and for neovascularisation. In this way, it is possible to combine the main properties that a three-dimensional scaffold should have for bone regeneration: interconnected and high porosity, adequate mechanical properties and bioactivity.     

Fabrication of a porous wall and higher interconnectivity scaffold comprising gelatin/chitosan via combination of salt-leaching and lyophilization methods

A novel gelatin/chitosan scaffold with higher porosity and interconnectivity was designed through salt-leaching/lyophilization (SLL) method. The properties of the fabricated scaffolds were compared with conventional scaffolds, which are obtained by thermally induced phase-separation (TIPS) method. The scaffolds made by phase-separation method have high tensile strength, but suffer from less channel interconnectivity, pore uniformity and also low surface porosity. The microstructure, porosity, phosphate-buffered saline (PBS) solution absorption and tensile strength of the prepared scaffolds by SLL method were studied. In this work, SLL as a two-step technique is introduced for creating porosity to improve both channel interconnectivity and pore uniformity for water-soluble polymers in comparison with the TIPS method. The SLL technique includes two mechanisms: the first, leaching of mixed sodium chloride crystals and particles created during recrystallization of the dissolved NaCl and the second, phase separation during lyophilization at the pore walls. These two steps in porosity formation lead to special pore morphology, which is more suitable for cell culturing because of higher interconnectivity and rich surface porosity in comparison with the phase-separated scaffolds. The prepared scaffolds, using this technique with different salt/polymer ratios and salt crystal size, have 91?C97% porosity and 94?C190???m mean pore size with tensile strength of 72?C215?kPa and PBS solution absorption between 12.4 and 19 times dry weight. The pore size of scaffolds prepared using the SLL method could be adjusted independently of polymer solution concentration. These scaffolds have a great potential in skin tissue engineering application.