Bioactive glass scaffolds have been used to heal small contained bone defects but
their application to repairing structural bone is limited by concerns about their
mechanical reliability. In the present study, the addition of an adherent polymer layer to
the external surface of strong porous bioactive glass (13–93) scaffolds was
investigated to improve their toughness. Finite element modeling (FEM) of the flexural
mechanical response of beams composed of a porous glass and an adherent polymer layer
predicted a reduction in the tensile stress in the glass with increasing thickness and
elastic modulus of the polymer layer. Mechanical testing of composites with structures
similar to the models, formed from 13–93 glass and polylactic acid (PLA), showed
trends predicted by the FEM simulations but the observed effects were considerably more
dramatic. A PLA layer of thickness −400 µm, equal to
−12.5% of the scaffold thickness, increased the load-bearing capacity of
the scaffold in four-point bending by ~50%. The work of fracture increased
by more than 10,000%, resulting in a non-brittle mechanical response. These
bioactive glass–PLA composites, combining bioactivity, high strength, high work of
fracture and an internal architecture shown to be conducive to bone infiltration, could
provide optimal implants for healing structural bone defects.