The design of porous scaffolds able to promote and guide cell proliferation, colonization, and biosynthesis in three dimensions is key determinant in bone tissue engineering (bTE). The aim of this study was to assess the role of the micro-architecture of poly(epsilon-caprolactone) scaffolds in affecting human mesenchymal stem cells' (hMSCs) spatial organization, proliferation, and osteogenic differentiation in vitro. Poly(epsilon-caprolactone) scaffolds for bTE and characterized by mono-modal and bi-modal pore size distributions were prepared by the combination of gas foaming and selective polymer extraction from co-continuous blends. The topological properties of the pore structure of the scaffolds were analyzed and the results correlated with the ability of hMSCs to proliferate, infiltrate, and differentiate in vitro in three dimensions. Results showed that the micro-architecture of the pore structure of the scaffolds plays a crucial role in defining cell seeding efficiency as well as hMSCs' three-dimensional colonization, proliferation, and osteogenic differentiation. Taken all together, our results indicated that process technologies able to allow a fine-tune of the topological properties of biodegradable porous scaffolds are essential for bTE strategies.

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One of the challenges in tissue engineering scaffold design is the realization of structures with a pre-defined multi-scaled porous network. Along this line, this study aimed at the design of porous scaffolds with controlled porosity and pore size distribution from blends of poly(epsilon-caprolactone) (PCL) and thermoplastic gelatin (TG), a thermoplastic natural material obtained by de novo thermoplasticization of gelatin. PCL/TG blends with composition in the range from 40/60 to 60/40 (w/w) were prepared by melt mixing process. The multi-phase microstructures of these blends were analyzed by scanning electron microscopy and dynamic mechanical analysis. Furthermore, in order to prepare open porous scaffolds for cell culture and tissue replacement, the TG and PCL were selectively extracted from the blends by the appropriate combination of solvent and extraction parameters. Finally, with the proposed combination of gas foaming and selective polymer extraction technologies, PCL and TG porous materials with multi-scaled and highly interconnected porosities were designed as novel scaffolds for new-tissue regeneration.

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This communication reports the design and fabrication of porous scaffolds of poly(ε-caprolactone) (PCL) and PCL loaded with hydroxyapatite (HA) nanoparticles with bimodal pore size distributions by a two step depressurization solid-state supercritical CO(2) (scCO(2) ) foaming process. Results show that the pore structure features of the scaffolds are strongly affected by the thermal history of the starting polymeric materials and by the depressurization profile. In particular, PCL and PCL-HA nanocomposite scaffolds with bimodal and uniform pore size distributions are fabricated by quenching molten samples in liquid N(2) , solubilizing the scCO(2) at 37 °C and 20 MPa, and further releasing the blowing agent in two steps: (1) from 20 to 10 MPa at a slow depressurization rate, and (2) from 10 MPa to the ambient pressure at a fast depressurization rate. The biocompatibility of the bimodal scaffolds is finally evaluated by the in vitro culture of human mesenchymal stem cells (MSCs), in order to assess their potential for tissue engineering applications.

Open-pore biodegradable foams with controlled porous architectures were prepared by combining gas foaming and microparticulate templating. Microparticulate composites of poly(epsilon-caprolactone) (PCL) and micrometric sodium chloride particles (NaCl), in concentrations ranging from 70/30 to 20/80 wt.-% of PCL/NaCl were melt-mixed and gas-foamed using carbon dioxide as physical blowing agent. The effects of microparticle concentration, foaming temperature, and pressure drop rate on foam microstructure were surveyed and related to the viscoelastic properties of the polymer/microparticle composite melt. Results showed that foams with open-pore networks can be obtained and that porosity, pore size, and interconnectivity may be finely modulated by optimizing the processing parameters. Furthermore, the ability to obtain a spatial gradient of porosity embossed within the three-dimensional polymer structure was exploited by using a heterogeneous microparticle filling. Results indicated that by foaming composites with microparticle concentration gradients, it was also possible to control the porosity and pore-size spatial distribution of the open-pore PCL foams.

In this study, we investigated the processing/structure/property relationship of multi-scaled porous biodegradable scaffolds prepared by combining the gas foaming and NaCl reverse templating techniques. Poly(ε-caprolactone) (PCL), hydroxyapatite (HA) nano-particles and NaCl micro-particles were melt-mixed by selecting different compositions and subsequently gas foamed by a pressure-quench method. The NaCl micro-particles were finally removed from the foamed systems in order to allow for the achievement of the multi-scaled scaffold pore structure. The control of the micro-structural properties of the scaffolds was obtained by the optimal combination of the NaCl templating concentration and the composition of the CO2-N2 mixture as the blowing agent. In particular, these parameters were accurately selected to allow for the fabrication of PCL and PCL-HA composite scaffolds with multi-scaled open pore structures. Finally, the biocompatibility of the scaffolds has been assessed by cultivating pre-osteoblast MG63 cells in vitro, thus demonstrating their potential applications for bone regeneration.

The aim of this study was the design of novel biodegradable porous scaffolds for bone tissue engineering (bTE) via supercritical CO 2 (scCO 2 ) foaming process. The porous scaffolds were prepared from a poly(ε-caprolactone)-thermoplastic zein multi-phase blend w/o interdispersed hydroxyapatite particles (HA) and the porous structure achieved via the scCO 2 foaming technology. The control of scaffolds porosity was obtained by modulating materials formulation and foaming temperature (T F ). The scaffolds were subjected to morphological, micro-structural and biodegradation analyses, as well as in vitro biocompatibility tests. Results demonstrated that both HA concentration and T F significantly affected the micro-structural features of the scaffolds.In particular, scaffolds with porosity and pore size distribution, mechanical properties and biodegradability adequate for bTE were designed and produced by selecting a T F equal to 100°C for all the compositions used. The biocompatibility of these scaffolds was assessed in vitro by using osteoblast-like MG63 and human mesenchymal stem cells (hMSCs).