Novel,simple and reproducible method for preparation of composite hierarchal porous structure scaffolds

Demand to develop a simple and adaptable method for preparation the hierarchical porous scaffolds for bone tissue regeneration is ever increasing. This study presents a novel and reproducible method for preparing the scaffolds with pores structure spanning from nano, micro to macro scale. A macroporous Sr-Hardystonite (Sr–Ca₂ZnSi₂O₇, Sr–HT) scaffold with the average pore size of ~ 1200 μm and porosity of ~ 95% was prepared using polymer sponge method. The struts of the scaffold were coated with a viscous paste consisted of salt (NaCl) particles and polycaprolactone (PCL) to provide a layer with thickness of ~ 300–800 μm. A hierarchical porous scaffold was obtained with macro, micro and nanopores in the range of 400–900 μm, 1–120 μm and 40–290 nm, after salt leaching process. These scales could be easily adjusted based on the starting foam physical characteristics, salt particle size, viscosity of the paste and salt/PCL weight ratio.     

Preparation of porous scaffold from hydroxyapatite powders

Hydroxyapatite (HA) powder was prepared by wet chemical method. The hydroxyapatite phase was stable up to 1250 °C without decomposition to beta-tricalcium phosphate. Interconnected porous hydroxyapatite scaffold resembling trabecular bone structure was developed from polymeric replica sponge method. The prepared scaffold has 60 vol.% porosity having a major fraction of ~ 50–125 μm pore diameter. The pore content, pore morphology, pore interconnectivity of scaffold and their compressive strength were dependent on the solid loading and binder content. In-vitro bioactivity and bioresorbability confirmed the feasibility of the developed scaffolds.     

Porous poly(vinyl alcohol)/sepiolite bone scaffolds: Preparation,structure and mechanical properties

Porous poly(vinyl alcohol) (PVA)/sepiolite nanocomposite scaffolds containing 0–10 wt.% sepiolite were prepared by freeze-drying and thermally crosslinked with poly(arylic acid). The microstructure of the obtained scaffolds was characterised by scanning electron microscopy and micro-computed tomography, which showed a ribbon and ladder like interconnected structure. The incorporation of sepiolite increased the mean pore size and porosity of the PVA scaffold as well as the degree of anisotropy due to its fibrous structure. The tensile strength, modulus and energy at break of the PVA solid material that constructed the scaffold were found to improve with additions of sepiolite by up to 104%, 331% and 22% for 6 wt.% clay. Such enhancements were attributed to the strong interactions between the PVA and sepiolite, the good dispersion of sepiolite nanofibres in the matrix and the intrinsic properties of the nanofibres. However, the tensile properties of the PVA scaffold deteriorated in the presence of sepiolite because of the higher porosity, pore size and degree of anisotropy. The PVA/sepiolite nanocomposite scaffold containing 6 wt.% sepiolite was characterised by an interconnected structure, a porosity of 89.5% and a mean pore size of 79 μm and exhibited a tensile strength of 0.44 MPa and modulus of 14.9 MPa, which demonstrates potential for this type of materials to be further developed as bone scaffolds.     

Thermal-crosslinked porous chitosan scaffolds for soft tissue engineering applications

The aim of this study was to demonstrate the feasibility of using a steam autoclave process for sterilization and simultaneously thermal-crosslinking of lyophilized chitosan scaffolds. This process is of great interest in biomaterial development due to its simplicity and low toxicity. The steam autoclave process had no significant effect on the average pore diameter (~ 70 μm) and overall porosity (> 80%) of the resultant chitosan scaffolds, while the sterilized scaffolds possessed more homogenous pore size distribution. The sterilized chitosan scaffolds exhibited an enhanced compressive modulus (109.8 kPa) and comparable equilibrium swelling ratio (23.3). The resultant chitosan scaffolds could be used directly for in vitro cell culture without extra sterilization. The data of in vitro studies demonstrated that the scaffolds facilitated cell attachment and proliferation, indicating great potential for soft tissue engineering applications.     

Processing and properties of porous titanium with high porosity coated by bioactive titania nanotubes

A porous titanium scaffold with a porosity of 70% and a pore size of about 200–300 μm was fabricated using the space-holder sintering process. Furthermore, the bioactive TiO₂ nanotubes with a tube size of approximately 100 nm were prepared successfully on the surface of the porous titanium by anodization and heat-treatment. The bioactivity of the scaffold was evaluated by immersing the samples into the simulated body fluid for 7 days. Results show that the porous titanium scaffold coated with anatase nanotubes has the superior ability of hydroxyapatite formation. Meanwhile, the scaffold has a high compressive strength of 36.8 MPa, which can be used as a cancellous bone substitute.     

The impact of Cu(II) ions doping in nanostructured hydroxyapatite powder: A finite element modelling study for physico-mechanical and biological property evaluation

The synthesis of doped nanostructured materials with multifunctional properties and improved biocompatibility have immense potential for biomedical applications. In this present study, a facile wet chemical precipitation method was employed to synthesize hydroxyapatite (HAp) and different concentrations copper doped HAp, and Cu_x-HAp (x = 1, 2, and 4 mol%) nano materials. Sophisticated analytical and spectroscopic techniques were employed to confirm its physico-chemical properties, and morphological features. The synthesized HAp, Cu_x-HAp were further studied as a drug nanocarrier using doxorubicin hydrochloride (DOX) as a model drug, which results a maximum drug release of ～34.3% (at pH 4.5) for 1 mol% of Cu-HAp. The nanostructured materials were further used to fabricate scaffolds by employing gel-casting method. The finite element modeling theoretical approach was adopted, to correlate the force distribution over the developed scaffold during mechanical characterization. The in vitro study confirmed the nontoxic behavior of the HAp and Cu_x-HAp scaffolds using MG-63 cell line. The developed scaffold effectively facilitates and simulates the new cell attachment, growth, and proliferation on its surface with adequate (～7.87 MPa) compressive strength properties. The enhanced biocompatibility with improved mechanical stability of Cu_x-HAp nanomaterials could address some of the critical challenges in biomedical applications.     

Fabrication of three-dimensional poly(ε-caprolactone) scaffolds with hierarchical pore structures for tissue engineering

The physical properties of tissue engineering scaffolds such as microstructures play important roles in controlling cellular behaviors and neotissue formation. Among them, the pore size stands out as a key determinant factor. In the present study, we aimed to fabricate porous scaffolds with pre-defined hierarchical pore sizes, followed by examining cell growth in these scaffolds. This hierarchical porous microstructure was implemented via integrating different pore-generating methodologies, including salt leaching and thermal induced phase separation (TIPS). Specifically, large (L, 200–300 μm), medium (M, 40–50 μm) and small (S, < 10 μm) pores were able to be generated. As such, three kinds of porous scaffolds with a similar porosity of ~ 90% creating pores of either two (LS or MS) or three (LMS) different sizes were successfully prepared. The number fractions of different pores in these scaffolds were determined to confirm the hierarchical organization of pores. It was found that the interconnectivity varied due to the different pore structures. Besides, these scaffolds demonstrated similar compressive moduli under dry and hydrated states. The adhesion, proliferation, and spatial distribution of human fibroblasts within the scaffolds during a 14-day culture were evaluated with MTT assay and fluorescence microscopy. While all three scaffolds well supported the cell attachment and proliferation, the best cell spatial distribution inside scaffolds was achieved with LMS, implicating that such a controlled hierarchical microstructure would be advantageous in tissue engineering applications.     

Facile fabrication of the porous three-dimensional regenerated silk fibroin scaffolds

In the present work, we report a new facile method to fabricate porous three-dimensional regenerated silk fibroin (RSF) scaffolds through n-butanol- and freezing-induced conformation transition and phase separation. The effects of RSF concentration, freezing temperature and n-butanol addition on the microstructure, the secondary structures of silk fibroin and apparent mechanical properties of the RSF scaffolds were investigated by SEM, ¹³C CP-MAS NMR spectra and mechanical testing, respectively. By adjusting the RSF concentration and n-butanol addition, the pore size of the scaffold could be controlled in the range from of 10 μm to 350 μm with 84%–98% of porosity. The tensile strength of the wet scaffold reached the maximum of 755.2 ± 33.6 kPa when the concentration of RSF solution was increased to 15% w/w. Moreover, post-treatment with ethanol further induced conformation transition of RSF from random coil or helix to β-sheet. The porous scaffolds prepared by this facile and energy-saving method with good biocompatibility will have great potential for application in tissue engineering.     

Biofabrication and in vitro study of hydroxyapatite/mPEG–PCL–mPEG scaffolds for bone tissue engineering using air pressure-aided deposition technology

The aims of this study were to fabricate biopolymer and biocomposite scaffolds for bone tissue engineering by an air pressure-aided deposition system and to carry out osteoblast cell culture tests to validate the biocompatibility of fabricated scaffolds. A mPEG–PCL–mPEG triblock copolymer was synthesized as a biopolymer material. Biocomposite material was composed of synthesized biopolymer and hydroxyapatite (HA) with a mean diameter of 100 μm. The weight ratio of HA added to the synthesized biopolymer was 0.1, 0.25, 0.5 and 1. The experimental results show that the maximum average compressive strength of biocomposite scaffolds, made of weight ratio 0.5, with mean pore size of 410 μm (porosity 81%) is 18.38 MPa which is two times stronger than that of biopolymer scaffolds. Osteoblast cells, MC3T3-E1, were seeded on both types of fabricated scaffolds to validate the biocompatibility using methylthianzol tetrazolium (MTT) assay and cell morphology observation. After 28 days of in vitro culturing, the seeded osteoblasts were well distributed in the interior of both types of scaffolds. Furthermore, MTT experimental results show that the cell viability of the biocomposite scaffold is higher than that of the biopolymer scaffold. This indicates that adding HA into synthesized biopolymer can enhance compressive strength and the proliferation of the osteoblast cell.     

Trabecular scaffolds created using micro CT guided fused deposition modeling

Free form fabrication and high resolution imaging techniques enable the creation of biomimetic tissue engineering scaffolds. A 3D CAD model of canine trabecular bone was produced via micro CT and exported to a fused deposition modeler, to produce polybutylene terephthalate (PBT) trabeculated scaffolds and four other scaffold groups of varying pore structures. The five scaffold groups were divided into subgroups (n = 6) and compression tested at two load rates (49 N/s and 294 N/s). Two groups were soaked in a 25 °C saline solution for 7 days before compression testing. Micro CT was used to compare porosity, connectivity density, and trabecular separation of each scaffold type to a canine trabecular bone sample. At 49 N/s the dry trabecular scaffolds had a compressive stiffness of 4.94 ± 1.19 MPa, similar to the simple linear small pore scaffolds and significantly more stiff (p < 0.05) than either of the complex interconnected pore scaffolds. At 294 N/s, the compressive stiffness values for all five groups roughly doubled. Soaking in saline had an insignificant effect on stiffness. The trabecular scaffolds matched bone samples in porosity; however, achieving physiologic connectivity density and trabecular separation will require further refining of scaffold processing.     

The effect of processing parameters and solid concentration on the mechanical and microstructural properties of freeze-casted macroporous hydroxyapatite scaffolds

The design and fabrication of macroporous hydroxyapatite scaffolds, which could overcome current bone tissue engineering limitations, have been considered in recent years. In the current study, controlled unidirectional freeze-casting at different cooling rates was investigated. In the first step, different slurries with initial hydroxyapatite concentrations of 7–37.5 vol.% were prepared. In the next step, different cooling rates from 2 to 14 °C/min were applied to synthesize the porous scaffold. Additionally, a sintering temperature of 1350 °C was chosen as an optimum temperature. Finally, the phase composition (by XRD), microstructure (by SEM), mechanical characteristics, and the porosity of sintered samples were assessed. The porosity of the sintered samples was in a range of 45–87% and the compressive strengths varied from 0.4 MPa to 60 MPa. The mechanical strength of the scaffolds increased as a function of initial concentration, cooling rate, and sintering temperature. With regards to mechanical strength and pore size, the samples with the initial concentration and the cooling rate of 15 vol.% and 5 °C/min, respectively, showed better results.     

Modification of porous calcium phosphate surfaces with different geometries of bioactive glass nanoparticles

In this study, the effects of bioactive glass nanoparticles' (nBGs) size and shape incorporated into hydroxyapatite/β-tricalcium phosphate (BCP) scaffolds were investigated. We prepared a highly porous (> 85%) BCP scaffold and coated its surface with a nanocomposite layer consisted of polycaprolactone (PCL) and rod (~ 153 nm in height and ~ 29 nm in width) or spherical (~ 33 nm and 64 nm in diameter) nBGs. Osteogenic gene expression by primary human osteoblast-like cells (HOB) was investigated using quantitative real time polymerase chain reaction (q-RT-PCR). We demonstrated for the first time that in vitro osteogenesis is dramatically affected by the shape of the nBGs, whereby rod shaped nBGs showed the most significant osteogenic induction, compared to spherical particles (regardless of their size). Importantly, the good biological effect observed for the rod shaped nBGs was coupled by a marked increase in the modulus (~ 48 MPa), compressive strength (~ 1 MPa) and failure strain (~ 6%), compared to those for the BCP scaffolds (~ 4 MPa, ~ 1 MPa and ~ 0.5% respectively). The findings of this study demonstrated that the shape of the nBGs is of significant importance when considering bone regeneration.     

Development,characterization, and in vitro bioactivity studies of sol–gel bioactive glass/poly(l-lactide) nanocomposite scaffolds

Developing materials combining the advantages of synthetic polymers and bioactive glass nanoparticles can provide an efficient bone engineering scaffold. In this study, sol–gel bioactive glass (SG) nanoparticles were synthesized by quick alkali-mediation; sol–gel derived bioactive glass/poly(l-lactide) nanocomposite scaffolds were then developed. The influence of the glass content on the porosity of nanocomposite scaffolds was evaluated by SEM. The results showed that the neat polymer scaffold (PLA) has a highly interconnected porous structure with a maximum pore size of about 250 μm. For the composite scaffold containing 25 wt.% glass (SGP25), the decrease in the maximum pore size, (to about 200 μm) was not significant while for the SGP50 composite scaffold containing 50 wt.% glass it was a significant decrease (to about 100 μm). The apparent porosity of the scaffolds was 56.56% ± 7.15, 54.14% ± 3.84, and 53.11% ± 3.99 for PLA, SGP25, and, SGP50 respectively. FT-IR, TGA, and XRD results revealed some interaction of the glass filler with the polymeric matrix in the scaffolds. The degradation study showed that, by increasing the glass content in the scaffolds, the water absorption decreased, the weight loss increased, and the cumulative ion concentrations released from them also increased. This indicates the possibility of modulating the degradation rate by varying the glass/polymer ratio. At the end of the incubation period, the weight losses were around 5.44% ± 0.96, 32.50% ± 2.73, and 41.47% ± 3.02 for the PLA, SGP25, and SGP50, respectively. Moreover, the water uptake reached 119.65% ± 18.88 and 93.39% ± 13.01 for SGP25 and SGP50, respectively. The addition of the SG to the scaffolds was found to enhance their in vitro bioactivity. Therefore, these nanocomposite scaffolds have a potential to be applied in bone engineering. All data are expressed as mean ± standard deviation (n = 3).     

Effect of ZrO2 addition on the mechanical properties of porous TiO2 bone scaffolds

This study aimed at the investigation of the effect of zirconium dioxide (ZrO₂) addition on the mechanical properties of titanium dioxide (TiO₂) bone scaffolds. The highly biocompatible TiO₂ has been identified as a promising material for bone scaffolds, whereas the more bioinert ZrO₂ is known for its excellent mechanical properties. Ultra-porous TiO₂ scaffolds (> 89% porosity) were produced using polymer sponge replication with 0–40 wt.% of the TiO₂ raw material substituted with ZrO₂. Microstructure, chemical composition, and pore architectural features of the prepared ceramic foams were characterised and related to their mechanical strength. Addition of 1 wt.% of ZrO₂ led to 16% increase in the mean compressive strength without significant changes in the pore architectural parameters of TiO₂ scaffolds. Further ZrO₂ additions resulted in reduction of compressive strength in comparison to containing no ZrO₂. The appearance of zirconium titanate (ZrTiO₄) phase was found to hinder the densification of the ceramic material during sintering resulting in poor intergranular connections and thus significantly reducing the compressive strength of the highly porous ceramic foam scaffolds.     

Gas anti-solvent precipitation assisted salt leaching for generation of micro- and nano-porous wall in bio-polymeric 3D scaffolds

The mass transport through biocompatible and biodegradable polymeric 3D porous scaffolds may be depleted by non-porous impermeable internal walls. As consequence the concentration of metabolites and growth factors within the scaffold may be heterogeneous leading to different cell fate depending on spatial cell location, and in some cases it may compromise cell survival.In this work, we fabricated polymeric scaffolds with micro- and nano-scale porosity by developing a new technique that couples two conventional scaffold production methods: solvent casting-salt leaching and gas antisolvent precipitation. 10–15 w/w solutions of a hyaluronic benzyl esters (HYAFF11) and poly-(lactic acid) (PLA) were used to fill packed beds of 0.177–0.425 mm NaCl crystals. The polymer precipitation in micro and nano-porous structures between the salt crystals was induced by high-pressure gas, then its flushing extracted the residual solvent. The salt was removed by water-wash. Morphological analysis by scanning electron microscopy showed a uniform porosity (~ 70%) and a high interconnectivity between porous. The polymeric walls were porous themselves counting for 30% of the total porosity. This wall porosity did not lead to a remarkable change in compressive modulus, deformation, and rupture pressure. Scaffold biocompatibility was tested with murine muscle cell line C2C12 for 4 and 7 days. Viability analysis and histology showed that micro- and nano-porous scaffolds are biocompatible and suitable for 3D cell culture promoting cell adhesion on the polymeric wall and allowing their proliferation in layers. Micro- and nano-scale porosities enhance cell migration and growth in the inner part of the scaffold.     

Development of bioresorbable Mg-substituted tricalcium phosphate scaffolds for bone tissue engineering

Mg-substituted tricalcium phosphate (β-TCMP) samples were prepared either by the solid-state reaction of CaHPO₄ (DCPA), CaCO₃ and MgO powder at 1000 °C, or by a two-step process: wet precipitation of a precursor and further calcination of the precursor. The transition temperature from β-Tricalcium Phosphate (TCP) to α-TCP increases with the increase of Mg²⁺ content in β-TCMP samples. A β-TCMP sample with 3 mol% Mg²⁺ has a β-TCP to α-TCP transition temperature above 1300 °C, which was then used to fabricate various β-TCMP scaffolds in this study. Interconnected porous β-TCMP ceramics, with pore size > 100 μm and relative density of ~ 81% to 84%, were developed by a replication method using polyurethane foam as a template; micropores were also found in the scaffold struts. β-TCMP ceramics with a porous structure in the center and a dense shell-like structure outside, mimicking human bone, were fabricated by a molding method. Dense β-TCMP ceramic rings were also produced with an average compressive strength of 129 MPa.     

Low temperature synthesis of hydroxyapatite nano-rods by a modified sol–gel technique

Hydroxyapatite (HAp) nano-rods were successfully synthesized by a modified sol–gel method using a solution of CaCl₂·2H₂O in water, along with a solution of H₃PO₄ in triethylamine and NH₄OH as starting materials. The Ca/P molar ratio was maintained at 1.67. The sol obtained was dried in an oven for 2 days at 100 °C after being dialyzed for 12 h. Pellets were made from the crystalline powders and immersed in simulated body fluid (SBF) to check its biocompatibility after 15, 45 and 180 days of immersion. The HAp powders and pellets were characterized by X-Ray Diffraction crystallography (XRD), Fourier transform Infrared spectroscopy (FTIR), scanning electron microscopy (SEM), and Transmission electron microscopy (TEM). The HAp nano-rods had an average diameter of 25 nm and length 110–120 nm. Immersion of the HAp pellets in SBF led to the formation of a highly porous interconnecting HAp layer on the surface. The porosity increased with increase in immersion time.     

Freeze dried cross linking free biodegradable composites with microstructures for tissue engineering and drug delivery application

Biodegradable laminated polymer composites of agarose (A), gelatin (G) and hydroxyapatite (HAp) having 3D network of interconnected pores (1–500 μm) were fabricated without using cross linking agents. The incorporation of HAp to A, G and AG had considerable influence on the swelling behaviour, drug release and haemolytic activity. A-HAp scaffolds demonstrated interconnected porosity with extended drug release. G-HAp scaffolds possessed enhanced mechanical property. AG-HAp scaffolds exhibited extended drug delivery, haemocompatibility and efficacy against Gram positive bacteria compared with G-HAp. Hence, AG-HAp composites could be used us a scaffold for tissue engineering and drug delivery system. This method provides non toxic, versatile and cost effective biodegradable scaffolds which could be used for various biomedical applications.     

Porous low modulus Ti40Nb compacts with electrodeposited hydroxyapatite coating for biomedical applications

Porous ß-type non-toxic Ti40Nb alloy was prepared by compaction of mechanically alloyed powder mixed with NaCl or Mg particles as space-holder material. The compacts with porosity of 36–80% demonstrated a very low Young's modulus of ~ 1.5–3 GPa and compression strength of ~ 10–35 MPa, which is suitable for potential implant material application. Porous samples were electrochemically covered with hydroxyapatite. The influence of the deposition time and of the electrolyte concentrations on the morphology of the hydroxyapatite coating was studied. It is demonstrated that a homogenous coating of hydroxyapatite crystals with different shape and size can be obtained on the surface of the porous samples.     

Biological evaluation of human hair keratin scaffolds for skin wound repair and regeneration

The cytocompatibility, in vivo biodegradation and wound healing of keratin biomaterials were investigated. For the purposes, three groups of keratin scaffolds were fabricated by freeze-drying reduced solutions at 2 wt.%, 4 wt.% and 8 wt.% keratins extracted from human hairs. These scaffolds exhibited evenly distributed high porous structures with pore size of 120–220 μm and the porosity > 90%. NIH3T3 cells proliferated well on these scaffolds in culture lasting up to 22 days. Confocal micrographs stained with AO visually revealed cell attachment and infiltration as well as scaffold architectural stability. In vivo animal experiments were conducted with 4 wt.% keratin scaffolds. Early degradation of subcutaneously implanted scaffolds occurred at 3 weeks in the outermost surface, in concomitant with inflammatory response. At 5 weeks, the overall porous structure of scaffolds severely deteriorated while the early inflammatory response in the outermost surface obviously subsided. A faster keratin biodegradation was observed in repairing full-thickness skin defects. Compared with the blank control, keratin scaffolds gave rise to more blood vessels at 2 weeks and better complete wound repair at 3 weeks with a thicker epidermis, less contraction and newly formed hair follicles. These preliminary results suggest that human hair keratin scaffolds are promising dermal substitutes for skin regeneration.