Enhanced Bone Healing in Critical-Sized Rabbit Femoral Defects: Impact of Helical and Alternate Scaffold Architectures

This study investigates the effect of scaffold architecture on bone regeneration, focusing on 3D-printed polylactic acid-bioceramic calcium phosphate (PLA-bioCaP) composite scaffolds in rabbit femoral condyle critical defects. We explored two distinct scaffold designs to assess their influence on bone healing and scaffold performance. Structures with alternate (0°/90°) and helical (0°/45°/90°/135°/180°) laydown patterns were manufactured with a 3D printer using a fused deposition modeling technique. The scaffolds were meticulously characterized for pore size, strut thickness, porosity, pore accessibility, and mechanical properties. The in vivo efficacy of these scaffolds was evaluated using a femoral condyle critical defect model in eight skeletally mature New Zealand White rabbits. Then, the results were analyzed micro-tomographically, histologically, and histomorphometrically. Our findings indicate that both scaffold architectures are biocompatible and support bone formation. The helical scaffolds, characterized by larger pore sizes and higher porosity, demonstrated significantly greater bone regeneration than the alternate structures. However, their lower mechanical strength presented limitations for use in load-bearing sites.

3D printing of silk microparticle reinforced polycaprolactone scaffolds for tissue engineering applications

Polycaprolactone (PCL) scaffolds have been widely investigated for tissue engineering applications, however, they exhibit poor cell adhesion and mechanical properties. Subsequently, PCL composites have been produced to improve the material properties. This study utilises a natural material, Bombyx mori silk microparticles (SMP) prepared by milling silk fibre, to produce a composite to enhance the scaffolds properties. Silk is biocompatible and biodegradable with excellent mechanical properties. However, there are no studies using SMPs as a reinforcing agent in a 3D printed thermoplastic polymer scaffold. PCL/SMP (10, 20, 30 wt%) composites were prepared by melt blending. Rheological analysis showed that SMP loading increased the shear thinning and storage modulus of the material. Scaffolds were fabricated using a screw-assisted extrusion-based additive manufacturing system. Scanning electron microscopy and X-ray microtomography was used to determine scaffold morphology. The scaffolds had high interconnectivity with regular printed fibres and pore morphologies within the designed parameters. Compressive mechanical testing showed that the addition of SMP significantly improved the compressive Young's modulus of the scaffolds. The scaffolds were more hydrophobic with the inclusion of SMP which was linked to a decrease in total protein adsorption. Cell behaviour was assessed using human adipose derived mesenchymal stem cells. A cytotoxic effect was observed at higher particle loading (30 wt%) after 7 days of culture. By day 21, 10 wt% loading showed significantly higher cell metabolic activity and proliferation, high cell viability, and cell migration throughout the scaffold. Calcium mineral deposition was observed on the scaffolds during cell culture. Large calcium mineral deposits were observed at 30 wt% and smaller calcium deposits were observed at 10 wt%. This study demonstrates that SMPs incorporated into a PCL scaffold provided effective mechanical reinforcement, improved the rate of degradation, and increased cell proliferation, demonstrating potential suitability for bone tissue engineering applications.

Thermoplastic polyurethane foams: From autoclave batch foaming to bead foam extrusion

Two ester-based and one ether-based thermoplastic polyurethane grades have been used to produce thermoplastic polyurethane foams. The foaming process comprised pressure-induced batch foaming, foam extrusion, and bead foam extrusion by using an underwater granulator. Foam density and morphological properties, such as cell size, cell size distribution, and cell density, were measured through different analytical methods. Through autoclave batch foaming a minimum cell size of 10 µm and density of 202 kg/m3 is obtained, which is lower than the densities previously reported in the literature for thermoplastic polyurethane. Extrusion foaming however could not achieve the same range of foam expansion given that the lowest density achieved is 635 kg/m3 and a minimum cell size equal to 46 µm. The production of thermoplastic polyurethane bead foams is also reported for the first time. The minimum density of the obtained foamed beads is 306 kg/m3 and the lowest cell size is 55 µm.

Preparation of microporous thermoplastic polyurethane by low-temperature supercritical CO2 foaming

Thermoplastic polyurethane possesses many special characteristics. Its flexibility, rigidity, and elasticity can be adjusted by controlling the ratio of soft segments to hard segments. Due to its versatile physical properties, thermoplastic polyurethane is commonly used in transportation, construction, and biomaterials. However, methods for thermoplastic polyurethane foam production using CO2 are still under investigation. We have previously prepared nanoporous thermoplastic polyurethane foam using commercially available thermoplastic polyurethane; however, in this study, thermoplastic polyurethane was synthesized using 4,4′-methylenebis(phenyl isocyanate), poly(propylene glycol) and 1,4-butanediol, without solvents, using a pre-polymer method. The properties of the synthesized thermoplastic polyurethane were characterized by Fourier transform infrared spectroscopy, thermal analysis, and their mechanical properties were measured. The synthesized thermoplastic polyurethane was foamed by batch foaming using supercritical CO2 as the blowing agent. The effect of saturation temperature and saturation time on the cell morphology of the thermoplastic polyurethane foam was examined.

Cell Structure, Density and Impact Strength of Cellulose Acetate Foamed with Supercritical Carbon Dioxide

This paper investigated the effects of processing conditions on the cell structure, density and impact strength of cellulose acetate (CA) foamed with supercritical carbon dioxide (SC-CO2). The scanning electron microscope (SEM) images show that there is the open-cell structure obviously when the foaming temperature exceeds 210°C, and the increasing foaming temperature improves the amount of open cells. The diameters of external cells range from 0.50 μm to 0.85 μm, and the diameters of internal cells are around 0.20 μm. The presence of cosolvents is beneficial to form open-cell structure, which is ascribed to more amount of CO2 dissolved into the CA matrix. Densities of foamed CA are measured with the method of volumetric flask, and the density ranges between 0.69 g·cm-3 and 1.02 g·cm-3, which are lower than that of the original sample (1.27 g·cm-3). The density decreases with increasing the saturation temperature, the saturation time or the foaming temperature. And densities with ethanol are much lower than those with acetone. Both of the impact strengths and specific impact strengths of foamed CA, higher than those of the original sample, increase firstly and decrease subsequently with increasing the foaming temperature. The impact strength of CA foaming at 230°C is 1.4 times higher than that of the original sample, and the specific impact strength increases by 84%.

Fabrication of porous synthetic polymer scaffolds for tissue engineering

Tissue engineering provides a novel and promising approach to replace damaged tissue with an artificial substitute. Porous synthetic biodegradable polymers are the preferred materials for this substitution due to their microstructure, biocompatibility, biodegradability, and low cost. As a crucial element in tissue engineering, a scaffold acts as an artificial extracellular matrix (ECM) and provides support for cell migration, differentiation, and reproduction. The fabrication of viable scaffolds, however, has been a challenge in both clinical and academic settings. Methods such as solvent casting/particle leaching, thermally induced phase separation (TIPS), electrospinning, gas foaming, and rapid prototyping (additive manufacturing) have been developed or introduced for scaffold fabrication. Each method has its own advantages and disadvantages. In this review, the commonly used synthetic polymer scaffold fabrication methods will be introduced and discussed in detail, and recent progress regarding scaffold fabrication—such as combining different scaffold fabrication methods, combining various materials, and improving current scaffold fabrication methods—will be reviewed as well.

Microcellular injection molding of polypropylene and glass fiber composites with supercritical nitrogen

Microcellular injection molding of polypropylene and glass fiber composites (PP-1684/GF-950) was performed using supercritical nitrogen as the physical blowing agent. Based on design of experiment matrices, the influences of glass fiber content and operating conditions on cell structure, glass fiber orientation and mechanical properties of molded samples were studied systematically. The results showed the cell morphology and glass fiber orientation of foaming parts were definitely influenced by the cooling and shear effects. The mechanical properties of foamed polypropylene–glass fiber composites could be effectively enhanced by improving the cell morphology, dispersion state and orientation of the glass fiber at optimal weight percentage [Formula: see text]. And the optimal conditions for injection molding were obtained by analyzing the signal-to-noise ratio analysis of the mechanical properties of the molded samples, which were a shot size of 36 mm, a supercritical N2 weight percentage of 0.4%, an injection speed of 60%, a melt temperature of 190℃ and a mold temperature of 70℃. The molded specimens of polypropylene–glass fiber composites, produced under those optimal conditions, exhibited very uniform fiber dispersion and microcellular structures with an average cell size less than 30 µm. And the mechanical properties normalized by weight ratio of the microcellular samples were increased significantly, especially the impact strength.

Characterization of thermoplastic polyurethane/polylactic acid (TPU/PLA) tissue engineering scaffolds fabricated by microcellular injection molding

Polylactic acid (PLA) and thermoplastic polyurethane (TPU) are two kinds of biocompatible and biodegradable polymers that can be used in biomedical applications. PLA has rigid mechanical properties while TPU possesses flexible mechanical properties. Blended TPU/PLA tissue engineering scaffolds at different ratios for tunable properties were fabricated via twin screw extrusion and microcellular injection molding techniques for the first time. Multiple test methods were used to characterize these materials. Fourier transform infrared spectroscopy (FTIR) confirmed the existence of the two components in the blends; differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) confirmed the immiscibility between the TPU and PLA. Scanning electron microscopy (SEM) images verified that, at the composition ratios studied, PLA was dispersed as spheres or islands inside the TPU matrix and that this phase morphology further influenced the scaffold's microstructure and surface roughness. The blends exhibited a large range of mechanical properties that covered several human tissue requirements. 3T3 fibroblast cell culture showed that the scaffolds supported cell proliferation and migration properly. Most importantly, this study demonstrated the feasibility of mass producing biocompatible PLA/TPU scaffolds with tunable microstructures, surface roughnesses, and mechanical properties that have the potential to be used as artificial scaffolds in multiple tissue engineering applications.