Control of the structure and mechanical property of porous WS<Subscript>2</Subscript> scaffold during freeze casting

Porous WS₂ scaffolds with aligned lamellar pore were fabricated by freeze casting, and the pore morphology and size can be well controlled by adjusting the processing parameters during freeze casting process. The results indicated that the porosity and the compressive strength of porous WS₂ were greatly affected by the concentration of gelatin. As the gelatin addition increased from 1 to 5 wt%, the porosity of porous WS₂ scaffolds with initial solid content of 3 vol% decreased from 95.12 to 90.23%, and their compressive strength increased from 0.22 to 1.16 MPa. Moreover, the lamellar spacing and wall thickness could be tailored from 90 to 320 and 5 to 30 μm respectively by changing the cooling temperature. And the compressive strength of scaffolds has a slight increase with the decreases of cooling temperature. The porous WS₂ scaffold with fine aligned lamellar structure and proper compressive strength are expected to be used for scaffold materials.     

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.     

Compressive strength and biomineralisation improvement by water glass coating on porous calcium phosphate scaffolds

Calcium phosphate (Ca–P) based scaffolds were found to be a favourable alternative for orthopaedic applications because of their similar chemical composition to natural bone. In this study, porous triphasic Ca–P scaffolds containing macropores (∽200?μm) interconnected with micropores (∽20?μm) were fabricated using an extrusion method. The hydroxyapatite/tricalcium phosphate ratio of the porous scaffolds was varied using different ratios of starting materials while keeping the Ca/P ratio fixed (1.5). A water glass coating on the porous Ca–P scaffolds increased the compressive strength by 45% without significantly decreasing the porosity of the H100D50 scaffold. The maximum compressive strength, ～15?MPa, was achieved on the H100D50 scaffold. The ability for apatite formation in simulated body fluid was amplified by the water glass coating on the sintered Ca–P scaffolds. Therefore, a water glass coating can be used to enhance the mechanical properties as well as the biomineralisation of the porous ceramic scaffolds.     

Development of porous ultra high molecular weight polyethylene scaffolds for the fabrication of orbital implant

Porous implants having interconnecting channels allow ingrowth of host connective tissue. Complete implant vascularization reduces the risk of infection, extrusion, and other complications associated with nonintegrated implants. Attempts were made to develop 60% and 70% porous ultra high molecular weight polyethylene (UHMWPE) scaffolds and blocks using sodium chloride as channeling agent, which when dissolved in boiling water leaves behind the interconnecting channels. The average diameter of the pores of 60% and 70% porous scaffolds was found to be approx. 170 μm and 210 μm, respectively. Mechanical characterizations of the scaffolds indicated sufficient strength to be used for orbital implant fabracation. Surface roughness of the scaffolds indicated increase in surface roughness with the increase in porosity. The scaffolds developed were found to be hemocompatible with the human blood. Subsequently, the 70% porous scaffold was dip coated with a solution mixture of sodium carboxy methyl cellulose (SCMC)/polyvinyl alcohol (PVA)/hydroxyapatite (HA) which also showed hemocompatibility. Ciprofloxacin release pattern from the membrane was determined. Finally an orbital implant was fabricated from the 70% porous scaffold.     

Structure control of hydroxyapatite ceramics via an electric field assisted freeze casting method

Using H₂O₂ aqueous solution as pore-forming agent, hydroxyapatite (HA) porous scaffolds with both lamellar and spherical pores were fabricated by a freeze casting method. The highest porosity was obtained in HA scaffolds prepared using 5 vol% H₂O₂ aqueous solution. The relationship between the electric field intensity and the properties of HA scaffolds was investigated. Results showed that when the electric field intensity was increased from 0 to 90 kV/m, the average diameters of lamellar and spherical pores of HA scaffold were increased from 460 μm to 810 μm, and from 320 μm to 420 μm, respectively. Vitro cellular assay indicated that HA scaffold with both the lamellar and the spherical pores has a better biocompatibility, compared with that with single pores.     

Effect of hexagonal structure nanoparticles on the morphological performance of the ceramic scaffold using analytical oscillation response

Porous bony scaffolds are utilized to manage the growth and migration of cells from adjacent tissues to a defective position. In the current investigation, the effect of titanium oxide (TiO₂) nanoparticles on mechanical and physical properties of porous bony implants made of polymeric polycaprolactone (PCL) is studied. The bio-nanocomposite scaffolds are prepared with composition of nanocrystalline hydroxyapatite (HA) and TiO₂ powder using the freeze-drying technique for different weight fractions of TiO₂ (0 wt%, 5 wt%, 10 wt%, and 15 wt%). In order to identify the microstructure and morphology of the fabricated porous bio-nanocomposites, the X-ray diffraction (XRD), atomic force microscope (AFM) and scanning electron microscopy (SEM) are employed. Also, the biocompatibility and biodegradability of the manufactured scaffolds are examined by placing them in a simulated body fluid (SBF) for 21 days, their weight and pH changes are measured. The rate of degradation of the PCL-HA scaffold can be controlled by varying the percentage of its constituent components. Due to an increasing growth and activity of bone cells and the apatite formation on the free surface of the fabricated bio-nanocomposite implants as well as their reasonable mechanical properties, they have the potential to be used as a bone substitute. Additionally, with the aid of the experimentally extracted mechanical properties of the scaffolds, the vibrational characteristics of a beam-type implant made of the proposed porous bio-nanocomposites are explored. The results obtained from SEM image indicate that the scaffolds produced by the employed method have high total porosity (70%–85%) and effective porosity. The pore size is obtained between 60 and 200 μm, which is desirable for the growth and propagation of bone cells. Also, it is revealed that the addition of TiO₂ nanoparticles leads to reduce the rate of dissolution of the fabricated bio-nanocomposite scaffolds.     

冷冻干燥法制备层状多孔羟基磷灰石支架过程中的溶剂升华行为

采用水基羟基磷灰石(hydroxyapatite,HA)浆料,经冷冻干燥和烧结工艺(1 250℃烧结3 h)制备了层状多孔HA支架.研究了冷冻温度、干燥压力和干燥温度对水基HA浆料中溶剂升华行为的影响.结果表明:随着冷冻温度的降低,多孔HA支架的层间距逐渐减小,支架的升华时间增加;由于样品的干燥过程同时受到传热和传质的...     

Ultrasonication‐Induced Modification of Hydroxyapatite Nanoparticles onto a 3D Porous Poly(lactic acid) Scaffold with Improved Mechanical Properties and Biocompatibility

A 3D porous poly(lactic acid) (PLA) scaffold with high porosity and well‐connected pores is fabricated using a vacuum‐assisted solvent casting technique. Its surface is modified with hydroxyapatite (HA) nanoparticles using ultrasonication to prepare an HA‐modified PLA/HA scaffold. For reference, an HA‐blended (b‐PLA‐HA) scaffold is fabricated via the solution blending method. The morphology, porosity, hydrophilicity, swelling ratio, mechanical properties, and cell viability of the PLA, b‐PLA‐HA, and PLA/HA scaffolds are systematically studied. The results show that HA nanoparticles are successfully introduced onto the surface of the PLA/HA scaffold, and strong interactions occur between the HA nanoparticles and the PLA matrix. The PLA/HA scaffold still has a high porosity of more than 85% after ultrasonication. The hydrophilicity and mechanical properties of the PLA/HA scaffold are significantly higher than those of the PLA and b‐PLA‐HA scaffolds. Compared with the PLA and b‐PLA‐HA scaffolds, the attachment and growth of mouse embryonic osteoblasts cells (MC3T3‐E1) cultured on the PLA/HA scaffold significantly improve, due to most HA nanoparticles on the surface, resulting in a good and direct interaction between the cells and the scaffold. Therefore, the PLA/HA scaffold possesses great potential to be used as a tissue engineering scaffold.     

Controlled freezing and freeze drying: a versatile route for porous and micro‐/nano‐structured materials

Freeze drying is a process whereby solutions are frozen in a cold bath and then the frozen solvents are removed via sublimation under vacuum, leading to formation of porous structures. Pore size, pore volume and pore morphology are dependent on variables such as freeze temperature, solution concentration, nature of solvent and solute, and the control of the freeze direction. Aqueous solutions, organic solutions, colloidal suspensions, and supercritical CO₂ solutions have been investigated to produce a wide range of porous and particulate structures. Emulsions have recently been employed in the freeze drying process, which can exert a systematic control on pore morphology and pore volume and can also lead to the preparation of organic micro‐ and nano‐particles. Spray freezing and directional freezing have been developed to form porous particles and aligned porous materials. This review describes the principles, latest progress and applications of materials prepared by controlled freezing and freeze drying. First of all the basics of freeze drying and the theory of freezing are discussed. Then the materials fabricated by controlled freezing and freeze drying are reviewed based on their morphologies: porous structures, microwires and nanowires, and microparticles and nanoparticles. The review concludes with new developments in this area and a brief look into the future. Copyright © 2010 Society of Chemical Industry     

A study on the fabrication of porous chitosan/gelatin network scaffold for tissue engineering

A novel porous chitosan/gelatin scaffold for tissue engineering was prepared via polyelectrolyte complex formation, freeze drying and post‐crosslinking with glutaraldehyde. The porosity and mean pore diameters could be controlled within 30∼100 µm by varying the original water content and the freezing conditions. Dipping the scaffolds in poly(lactic acid) provided good mechanical properties making it a promising candidate towards tissue engineering. © 2000 Society of Chemical Industry     

Self-supported ceramic substrates with directional porosity by mold freeze casting

Manufacture of thin-film ceramic substrates with high permeability and robustness is of high technological interest. In this work thin (green state thickness ∼500 μm) porous yttria-stabilized zirconia self-supported substrates were fabricated by pouring stable colloidal aqueous suspensions in a mold and applying directional freeze casting. Use of optimized suspension, cryoprotector additive and mold proved to deliver defect free ceramic films with high dimensional control. Microstructure analysis demonstrated the formation of desirable aligned porosity at macro-structural scale and resulted to be highly dependent on colloidal behaviour and freeze casting conditions. Manufactured green films were joined by lamination at room temperature and sintered to obtain symmetrical cells consisting of two porous self-supported substrate electrodes (∼420 μm) and dense yttria stabilized zirconia electrolyte (∼10 μm).     

Effects of formaldehyde solution and nanoparticles on mechanical properties and biodegradation of gelatin/nano β-TCP scaffolds

In this study, gelatin/beta tricalcium phosphate (β-TCP) nanocomposite scaffolds were prepared by solvent casting method. The cross-linking method was carried out by adding formaldehyde to gelatin. The microparticles of sodium chloride were used as porogen agent. Characterization of nano β-TCP was performed using XRD, FTIR, and SEM. Results showed that the size of the particles is about 100 nm with spherical morphology. In addition, the scaffold characterization was carried out using FTIR and SEM techniques. Observations showed a porous texture with pore size between 100 and 400 μm. The biodegradability and bioactivity evaluations of the scaffolds were done by immersing them in a simulated body fluid solution for different time periods. The biodegradability studies demonstrated a reduction in the degradation rate of gelatin/β-TCP nanocomposite scaffolds due to the presence of β-TCP nanoparticles. The obtained results of bioactivity tests confirmed the formation of apatite layer on the surface of the scaffolds. Furthermore, the effects of porosity, cross-linking agent, and β-TCP nanoparticles on the bending and compressive properties of the composite scaffolds were examined. According to the mechanical examinations of the scaffolds, the best bending and compressive properties occurred in the presence of 10 and 20 wt% of β-TCP nanoparticles, respectively. The appropriate mechanical properties and biodegradation rate for tissue engineering applications obtained at 1 g of the formaldehyde solution.     

Microstructure and mechanical properties of ZrB2–SiC porous ceramic by camphene-based freeze casting

Camphene-based freeze casting technique was adopted to fabricate ZrB₂–SiC porous ceramic with 3-dimensional (3D) pore network. ZrB₂–SiC/camphene slurries (initial solid loading: 20 vol%, 25 vol% and 30 vol%) were prepared for freeze casting. Regardless of initial solid loading, the fabricated sample had dense/porous dual microstructure. The thickness of dense layer was about 200–300 μm. The microstructures of ZrB₂–SiC porous ceramics were significantly influenced by the initial solid loading, which determines the pore size, porosity and mechanical properties of the final products.     

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。     

Porous SiC using polycarbosilane/camphene solutions: Roles of freeze casting parameters

In order to control the pore characteristics and macroscopical performance of porous ceramics, roles of the freeze casting parameters are the key points. Herein, aligned dendritic porous SiC was fabricated by freeze casting of PCS-camphene solutions with different solid loading, freeze front velocity, temperature gradient, and freezing temperature. Influence of these parameters on the microstructure and compressive strength of porous SiC was investigated. With increasing the PCS content, freeze temperature, freeze front velocity or temperature gradient, degree of undercooling of the camphene was increased, resulting in the formation of smaller pore size, decreased porosity and increased compressive strength. Compared to variables of freeze temperature and temperature gradient, increased freeze front velocity was more efficiency in improving the compressive strength of porous SiC, owing to the formation of smaller pore size and longer secondary dendritic crystals. Promising micron-sized porous SiC with high porosity (79.93 vol%) and satisfactory strength (15.84 MPa) was achieved for 10% PCS-camphene solution under optimized freezing conditions.     

Porous hydroxyapatite scaffolds produced by the combination of the gel-casting and freeze drying techniques

A technique combining gel-casting and freeze drying methods is introduced to prepare porous hydroxyapatite scaffolds which allow for better control of the scaffold microstructure and have improved mechanical properties. A monomeric system which is known to be a suitable gelling agent for setting ceramic suspensions into dense forms was selected to produce ceramic foams. Different concentrations of sodium lauryl sulphate solution were added into the hydroxyapatite gel suspension as a pore former. The effect of the solid content on the mechanical properties of the scaffold was also investigated. Rapid freezing with liquid nitrogen was performed according to the freeze drying technique and the porous structure and morphology of the scaffolds were analyzed by scanning electron microscopy. The mechanical properties of the hydroxyapatite scaffolds were determined by testing compressive strength using a universal testing machine. The prepared scaffolds were characterized by well-defined pore connectivity along with directional, uniform and completely open porosity. The maximum compressive strength of about 17?MPa obtained from the suspension consisted of 50% solid content with 20% concentration of sodium lauryl sulphate solution. The results show that sodium lauryl sulphate solution plays a significant role in changing the pore structure of hydroxyapaite scaffolds in systems having high solid content.     

Preparation of high strength lamellar porous calcium silicate ceramics by directional freeze casting

In this study, porous calcium silicate (CS) ceramics with oriented arrangement of lamellar macropore structure were prepared by directional freeze casting method. The lamellar macropores were connected by the micropores on the pore wall, which had good pore interconnectivity. The effects of solid loading of the slurry, freezing temperature, sintering additive content, and sintering temperature on the microstructures and compressive strength of the synthesized porous materials were investigated systematically. The results showed that with the increase of solid loading (≤20 vol%) and sintering additive content, the sizes of lamellar pores and pore walls increased gradually, the open porosity decreased and the compressive strength increased. The sintering temperature had little effect on the pore size of the ceramics, but increasing the sintering temperature (≤1050 °C) promoted the densification of the pore wall, reduced the porosity, and improved the strength. The decrease of freezing temperature had little effect on porosity, but it reduced the size of lamellar pore and pore wall, so as to improve the strength. Finally, porous CS ceramics with lamellar macropores of about 300–600 μm and 2–10 μm micropores on the pore wall were obtained. The porous CS ceramics had high pore interconnectivity, an open porosity of 66.25% and a compressive strength of 5.47 MPa, which was expected to be used in bone tissue engineering.     

Mechanical properties of porous ceramic scaffolds: Influence of internal dimensions

Highly porous ceramic scaffolds have been fabricated from a 70% SiO₂–30% CaO glass powder using stereolithography and the lost-mould process combined with gel-casting. After sintering at 1200 °C the glass crystallised to a structure of wollastonite and pseudowollastonite grains in a glassy matrix with a bulk porosity of 1.3%. All scaffolds had a simple cubic strut structure with an internal porosity of approximately 42% and internal pore dimensions in the range 300–600 μm. The mean crushing strength of the scaffolds is in the range 10–25 MPa with the largest pore sizes showing the weakest strengths. The variability of scaffold strengths has been characterised using Weibull statistics and each set of scaffolds showed a Weibull modulus of m≈3 independent of pore size. The equivalent strength of the struts within the porous ceramics was estimated to be in the range 40–80 MPa using the models of the Gibson and Ashby. These strengths were found to scale with specimen size consistent with the Weibull modulus obtained from compression tests. Using a Weibull analysis, these strengths are shown to be in accordance with the strength of 3-point bend specimens of the bulk glass material fabricated using identical methods. The strength and Weibull modulus of these scaffolds are comparable to those reported for other porous ceramic scaffold materials of similar porosity made by different fabrication routes.     

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.     

Control of pore structure during freeze casting of porous SiC ceramics by different freezing modes

The frozen moulds, including homogeneous, unidirectional and bidirectional freezing, were designed using materials with different thermal conductivities, and the temperature variations of the moulds and samples during the freezing process were simulated by finite element analysis. Highly porous SiC ceramics with significant differences in pore structure were fabricated by using the SiC/water slurries prepared via uniform or oriented freeze casting with various freezing modes, and porosity and compressive strength of the as-fabricated ceramics were investigated. The results showed that the pore structure of ceramics prepared by homogeneous freezing was relatively intricate and inconsistent, and had a higher compressive strength. In contrast, the pore structure of ceramics fabricated using bidirectional freezing mode was more ordered and higher porosity was observed. Moreover, porous ceramics prepared by unidirectional freezing mode exhibited a typical gradient structure with increased pore size from tens of micrometers in the bottom to hundreds of micrometers in the top.