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Successes in scaffold guided tissue engineering require scaffolds to have speci c macroscopic geometries and internal architectures to provide the needed biological and biophysical functions. Freeform fabrication provides an effective process tool to manufacture many advanced scaffolds with designed properties. This paper reports our recent study on using a novel precision extruding deposition (PED) process technique to directly fabricate cellular poly-ecaprolactone (PCL) scaffolds. Scaffolds with a controlled pore size of 250 m m and designed structural orientations were fabricated.

Bone tissue engineering is an emerging field providing viable substitutes for bone regeneration. Recent advances have allowed scientists and engineers to develop scaffolds for guided bone growth. However, success requires scaffolds to have specific macroscopic geometries and internal architectures conducive to biological and biophysical functions. Freeform fabrication provides an effective process tool to manufacture three-dimensional porous scaffolds with complex shapes and designed properties. A novel precision extruding deposition (PED) technique was developed to fabricate polycaprolactone (PCL) scaffolds. It was possible to manufacture scaffolds with a controlled pore size of 350 microm with designed structural orientations using this method. The scaffold morphology, internal micro-architecture and mechanical properties were evaluated using scanning electron microscopy (SEM), micro-computed tomography (micro-CT) and mechanical testing, respectively. An in vitro cell-scaffold interaction study was carried out using primary fetal bovine osteoblasts. Specifically, the cell proliferation and differentiation was evaluated by Alamar Blue assay for cell metabolic activity, alkaline phosphatase activity and osteoblast production of calcium. An in vivo study was performed on nude mice to determine the capability of osteoblast-seeded PCL to induce osteogenesis. Each scaffold was implanted subcutaneously in nude mice and, following sacrifice, was explanted at one of a series of time intervals. The explants were then evaluated histologically for possible areas of osseointegration. Microscopy and radiological examination showed multiple areas of osseous ingrowth suggesting that the osteoblast-seeded PCL scaffolds evoke osteogenesis in vivo. These studies demonstrated the viability of the PED process to fabricate PCL scaffolds having the necessary mechanical properties, structural integrity, and controlled pore size and interconnectivity desired for bone tissue engineering.

PurposeTo shift from rapid prototyping (RP) to agile fabrication by broadening the material selection, e.g. using ceramics, hence improving the properties (e.g. mechanical properties) of fused deposition modeling (FDM) products.Design/methodology/approachThis paper presents the development of a novel extrusion system, based on the FDM technology. The new set‐up, consisting of a mini‐extruder mounted on a high‐precision positioning system, is fed with bulk material in granulated form, instead that with the more common filament.FindingsPrevious research showed that the applications of new materials with specific characteristics in a commercial FDM system are limited by the use of intermediate precursors, i.e. a filament. The new design described in this paper overcomes the problem thanks to the new feeding system.Research limitations/implicationsThe work presented in this paper is only the starting point for further development. The new system design was tested and encouraging improvements of the final product were achieved. However, several parameters, e.g. size of the feeding granules, still need to be optimized.Practical implicationsThis configuration opens up opportunities for the use of wider range of materials, making the FDM to become a viable alternative manufacturing process for specialty products.Originality/valueThe mini‐extruder deposition system developed in this study exploits the advantages of the RP technologies: ability to shorten the product design and development time; suitability for automation; and ability to build many geometrically complex shapes. Hence, applying the described technology, it will be possible to manufacture customer‐driven product with important cost and time (from design to final product) savings.

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Bone tissue engineering is an emerging field providing viable substitutes for bone regeneration. Freeform fabrication provides an effective process tool to manufacture scaffolds with complex shapes and designed properties. We developed a novel precision extruding deposition (PED) technique to fabricate composite polycaprolactone∕hydroxyapatite (PCL∕HA) scaffolds. 25% concentration by weight of HA was used to reinforce 3D scaffolds. Two groups of scaffolds having 60% and 70% porosities and with pore sizes of 450μm and 750μm respectively, were evaluated for their morphology and compressive properties using scanning electron microscopy and the mechanical testing. In vitro cell-scaffold interaction study was carried out using primary fetal bovine osteoblasts. The cell proliferation and differentiation were evaluated by Alamar Blue assay and alkaline phosphatase activity. Our results suggested that compressive modulus of PCL∕HA scaffold was 84MPa for 60% porous scaffolds and was 76MPa for 70% porous scaffolds. The osteoblasts were able to migrate and proliferate for the cultured time over the scaffolds. Our study demonstrated the viability of the PED process to fabricate PCL scaffolds having necessary mechanical property, structural integrity, controlled pore size, and pore interconnectivity desired for bone tissue engineering.