Due to the synergic feature of individual components in hybrid (nano)biomaterials, their application in regenerative medicine has drawn significant attention. Aiming to address all the current challenges of aerogel as a potent scaffold in bone tissue engineering application, we adopted a novel synthesis approach to synergistically improve the pore size regime and mechanical strength in the aerogel. The three-dimensional aerogel scaffold in this study has been synthesized through a versatile one-pot aqueous-based sol−gel hybridization/assembly of organosilane (tetraethyl orthosilicate) and silk fibroin (SF) biopolymer, followed by unidirectional freeze-casting of the as-prepared hybrid gel and supercritical drying. The developed ultralight silica-SF aerogel hybrids demonstrated a hierarchically organized porous structure with interesting honeycomb-shaped micromorphology and microstructural alignment (anisotropy) in varied length scales. The average macropore size of the hybrid aerogel lied in ∼0.5−18 μm and was systematically controlled with freeze-casting conditions. Together with high porosity (91−94%), high Young's modulus (∼4−7 MPa, >3 order of magnitude improvement compared to their pristine aerogel counterparts), and bone-type anisotropy in the mechanical compressive behavior, the silica-SF hybrid aerogel of this study acted as a very competent scaffold for bone tissue formation. The results of in vitro assessments revealed that the silica-SF aerogel is not only cytocompatible and nonhemolytic but also acted as an open porous microenvironment to trigger osteoblast cell attachment, growth, and proliferation on its surface within 14 days of incubation. Moreover, to support the in vitro results, in vivo bone formation within the aerogel implant in the bone defect site was studied. The X-ray radiology and microcomputed tomography analyses confirmed that a significant new bone tissue density formed in the defect site within 25 days of implantation. Also, in vivo toxicology studies showed a zero-toxic impact of the aerogel implant on the blood biochemical and hematological parameters. Finally, the study clearly shows the potential of aerogel as a bioactive and osteoconductive open porous cellular matrix for a successful osseointegration process.

Thanks to the exceptional materials properties of silica aerogels, this fascinating highly porous material has found high-performance and real-life applications in various modern industries. However, a requirement for a broadening of these applications is based on the further improvement of the aerogel properties, especially with regard to mechanical strength and postsynthesis processability with minimum compromise to the other physical properties. Here, we report an entirely novel, simple, and aqueous-based synthesis approach to prepare mechanically robust aerogel hybrids by cogelation of silk fibroin (SF) biopolymer extracted from silkworm cocoons. The synthesis is based on sequential processes of acid catalyzed (physical) cross-linking of the SF biopolymer and simultaneous polycondensation of tetramethylorthosilicate (TMOS) in the presence of 5-(trimethoxysilyl)pentanoic acid (TMSPA) as a coupling agent and subsequent solvent exchange and supercritical drying. Extensive characterization by solid-state H NMR,Si NMR, and 2D H-Si heteronuclear correlation (HETCOR) MAS NMR spectroscopy as well as various microscopic techniques (SEM, TEM) and mechanical assessment confirmed the molecular-level homogeneity of the hybrid nanostructure. The developed silica-SF aerogel hybrids contained an improved set of material properties, such as low density (ρ = 0.11-0.2 g cm), high porosity (∼90%), high specific surface area (∼400-800 m g), and excellent flexibility in compression (up to 80% of strain) with three orders of magnitude improvement in the Young's modulus over that of pristine silica aerogels. In addition, the silica-SF hybrid aerogels are fire retardant and demonstrated excellent thermal insulation performance with thermal conductivities (λ) of 0.033-0.039 W m K. As a further advantage, the formulated hybrid silica-SF aerogel showed an excellent printability in the wet state using a microextrusion-based 3D printing approach. The printed structures had comparable properties to their monolith counterparts, improving postsynthesis processing or shaping of the silica aerogels significantly. Finally, the hybrid silica-SF aerogels reported here represent significant progress for a mechanically customized and robust aerogel for multipurpose applications, namely, as a customized thermal insulation material or as a dual porous open-cell biomaterial used in regenerative medicine.

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