Scaffold design and fabrication technologies for engineering tissues--state of the art and future perspectives

Elastic cartilage engineering using novel scaffold architectures in combination with a biomimetic cell carrier

Tissue engineering of an elastic cartilage graft that meets the criterion for both structural and functional integration into host tissue, as well as allowing for a clinically tolerable immune response, is a challenging endeavour. Conventional scaffold technologies have limitations in their ability to design and fabricate complex-shaped matrix architectures of structural and mechanical equivalence to elastic cartilage found in the body. We attempted to investigate the potential of conventionally isolated and passaged chondrocytes (2D environment) when seeded and cultured in combination with a biomimetic hydrogel in a mechanically stable and biomimetic composite matrix to form elastic cartilage within ectopic implantation sites. In vitro cultured scaffold/hydrogel/chondrocytes constructs showed islets of cartilage and mineralized tissue formation within the cell-seeded specimens in both pig and rabbit models. Specimens with no cells seeded showed only vascularized fibrous tissue ingrowth. These studies demonstrated the potential of such scaffold/hydrogel/cell constructs to support chondrogenesis in vivo. However, it also showed that even mechanically stable scaffolds do not allow regeneration of a large mass of structural and functional cartilage within a matrix architecture seeded with 2D passaged chondrocytes in combination with a cell biomimetic carrier. Hence, future experiments will be designed to evaluate an initial 3D culture of chondrocytes, effect on cell phenotype and their subsequent culture within biomimetic 3D scaffold/cell constructs.

Thermal and mechanical characteristics of poly(L-lactic acid) nanocomposite scaffold

Inorganic nanosized silicate nanoplatelets were incorporated into biodegradable poly(L-lactic acid) (PLLA) for the purpose of tailoring mechanical stiffness of PLLA porous scaffold systems. Increasing the nucleation density around the foreign body surfaces, the montmorillonite (MMT) nanoplatelets modified with dimethyl dihydrogenated tallow ammonium cations decreased the glass transition temperature and the degree of PLLA crystallinity, which seemingly caused the accelerated biodegradation rate of PLLA nanocomposites due to the enhanced segmental mobility of backbone chains and the expanded amorphous region of PLLA matrix. The tensile modulus was increased from 121.2MPa of pristine polymer scaffold to 170.1MPa of MMT/PLLA nanocomposite scaffold (ca. 40% increment) by the addition of small amount of MMT platelets (5.79 vol%) acting as a mechanical reinforcement of polymer chains in the nanoscale molecular level. Overall, the nanotechnology used in this study may be applied to various scaffold systems of biodegradable polymers and hard/soft scaffold structures requiring critical control and design characteristics of mechanical stiffness and biodegradation rate.

Modification of gene expression induced in human osteogenic and osteosarcoma cells by culture on a biphasic calcium phosphate bone substitute

Bone hybrids made of bioceramics seeded with mesenchymal or osteoblastic cells are very promising alternatives to autologous bone graft. Along this line, the development of in vitro models, dedicated to analyze the influence of these biomaterials on osteogenic cells, will help to improve the performance of these bone substitutes. In the present work we analyzed the effects of a macroporous biphasic calcium phosphate ceramic (BCP, Triosite) on three different human osteosarcoma cell lines and on human primary osteogenic cells and compared this culture substratum to traditional culture on plastic. We showed that all these osteoblastic cells adhere and proliferate on the trabecular BCP blocks, with a different spatial organization for osteosarcoma cells compared to normal osteogenic cells. We also demonstrated that osteoblastic marker genes such as Cbfa1, type I collagen, osteonectin, osteopontin, and osteocalcin were expressed at similar levels by these cells cultured on either substratum, suggesting that adhesion to BCP does maintain the osteoblastic phenotype of these cells. Next, we provided the first evidence of differences of cytokine expression profiles revealed on this Ca-P ceramic as compared to expression in classical culture. These modifications affected the expression of cytokines such as TGF-beta1, G-CSF, and IL-3 and were quantitatively different between osteosarcoma cells and normal osteogenic cells. Given the role of these cytokines in bone biology and in hematopoiesis, these results obtained in vitro suggest that the BCP ceramic studied here could stimulate osteogenesis in vivo by activating cellular processes during bone formation and healing. This study highlights the notion that the nature of the culture substratum must be taken into account when studying bone cell biology in vitro. Owing to the nature and spatial organization of the BCP, our hypothesis is that culture on BCP is closer to the physiological situation than culture on plastic.

Porous polymeric structures for tissue engineering prepared by a coagulation, compression moulding and salt leaching technique

A technique for the preparation of porous polymeric structures involving coagulation, compression moulding and particulate leaching has been developed. The technique combines the advantages of thermal processing methods and particulate leaching. A high molecular weight polymer solution in an organic solvent containing dispersed water-soluble salt particles is precipitated into an excess of non-solvent. The polymer-salt composite is then processed by thermal processing methods into devices of varying shapes and sizes, which can subsequently be extracted to give the desired porous structures. The porosities of the scaffolds could be varied between 70% and 95% by adjusting the polymer to salt ratio and the pore size could be controlled independently by varying the leachable particle size. This versatility provides for the optimisation of scaffolds used in medicine and in tissue engineering. Compared with commonly used porosifying methods such as sintering, compression moulding combined with salt leaching, and freeze-drying, this process allows excellent control over pore size and porosity and yields scaffolds with a much more homogeneous pore morphology. We have prepared porous structures from several relevant polymers in the biomedical field: poly(D,L-lactide), poly(epsilon-caprolactone) and 1000PEOT70PBT30, a segmented poly(ether ester) based on polyethylene oxide and polybutylene terephthalate.

Use of stereolithography to manufacture critical-sized 3D biodegradable scaffolds for bone ingrowth

A novel approach to the manufacture of biodegradable polymeric scaffolds for tissue-engineering utilizing stereolithography (SLA) is presented. SLA is a three-dimensional (3D) printing method that uses an ultraviolet laser to photo-crosslink a liquid polymer substrate. The current generation of SLA devices provide a 3D printing resolution of 0.1 mm. The experiments utilized a biodegradable resin mixture of diethyl fumarate (DEF), poly(propylene fumarate) (PPF), and a photoinitiator, bisacylphosphine oxide (BAPO). The PPF is crosslinked with the use of the SLA's UV laser (325-nm wavelength). An SLA device was retrofitted with a custom fixture build tank enclosing an elevator-driven build table. A 3D prototype model testing the manufacturing control this device provides was created in a computer-aided-design package. The resulting geometric data were used to drive the SLA process, and a DEF/PPF prototype part was successfully manufactured. These scaffolds have application in the tissue engineering of bony substrates.

Rabbit calvarial wound healing by means of seeded Caprotite scaffolds

Autologous bone is the most successful bone-grafting material; however, limited supply and donor site morbidity are problematic. Synthetic bone substitutes are effective, but healing is slow and unpredictable. Osseous wound healing may be enhanced if bone substitutes are combined with autologous bone marrow cells. To test this hypothesis, we created 40 calvarial defects in 20 12-week-old New Zealand White rabbits, divided into four groups: (1) unrepaired controls, (2) autologous bone grafts, (3) unseeded Caprotite (a polymer-ceramic composite) grafts, and (4) Caprotite grafts seeded with autologous bone marrow stromal cells. CT scans were obtained at 0, 6, and 12 weeks post-operatively, and defects were harvested for histology. Defects repaired with autologous bone had significantly (p < 0.05) more bone than the other three groups, although seeded Caprotite defects showed different wound-healing sequelae. Results suggest that seeded Caprotite scaffolds did not significantly enhance osseous defect healing compared with controls.

Design and fabrication of standardized hydroxyapatite scaffolds with a defined macro-architecture by rapid prototyping for bone-tissue-engineering research

This investigation describes the production and characterization of calcium phosphate scaffolds with defined and reproducible porous macro-architectures and their preliminary in vitro and in vivo bone-tissue-engineered response. Fugitive wax molds were designed and produced using a rapid prototyping technique. An aqueous hydroxyapatite slurry was cast in these molds. After sintering at 1250 degrees C and then cleaning, dimensional and material characterizations of the scaffolds were performed. The resulting scaffolds represented the design, and their dimensions were remarkably consistent. A texture inherent to the layer-by-layer production of the mold was impressed onto the vertical surfaces of the scaffolds. The surface roughness (R(a)) of the textured surfaces was significantly greater than that of the nontextured surfaces. Material analyses revealed a beta-TCP phase in addition to hydroxyapatite for the molded ceramics. Non-molded control ceramics exhibited only hydroxyapatite. Thirty scaffolds were seeded with culture-expanded goat bone-marrow stromal cells (BMSCs) and implanted subcutaneously in nude mice for 4 or 6 weeks. Histology revealed mineralized bone formation in all the scaffolds for both implantation periods. After 4 weeks, bone was present primarily as a layer on scaffold surfaces. After 6 weeks, the surface bone formation was accompanied by bone budding from the surface and occasional bridging of pores. This budding and bridging bone formation almost always was associated with textured scaffold surfaces. However, the area percentage of bone in pores was similar for the 4- and 6-week implantation periods.

Optimal design and fabrication of scaffolds to mimic tissue properties and satisfy biological constraints

Bone tissue engineering scaffolds must shape regenerating tissue, provide temporary mechanical support and enhance tissue regeneration. These requirements result in conflicting design goals. For example, increased temporary mechanical function requires a dense scaffold while enhanced cell/gene delivery requires a porous scaffold. This paper demonstrates an image-based homogenization optimization approach that can design scaffold microstructure, scaffold material and regenerate tissue microstructure to meet conflicting design requirements. In addition, constraints to ensure adequate cell/gene delivery can be introduced using a minimum porosity threshold. Homogenization theory was used to compute relationships between scaffold microstructure and effective stiffness. The functional relationships were used in the MATLAB optimization toolbox to compute optimal pore dimensions and scaffold material such that the scaffold and regenerate tissue effective stiffness matched that of native bone stiffness. The scaffold design was converted into STL format for solid free-form fabrication. Scaffolds were designed that matched mandibular condyle trabecular bone properties. Results showed excellent agreement between native bone properties and designed scaffold properties (all R2 > 0.89). Finally, example scaffolds were built from hydroxyapatite using a SFF casting technique.

Fused deposition modeling of novel scaffold architectures for tissue engineering applications

Fused deposition modeling, a rapid prototyping technology, was used to produce novel scaffolds with honeycomb-like pattern, fully interconnected channel network, and controllable porosity and channel size. A bioresorbable polymer poly(epsilon-caprolactone) (PCL) was developed as a filament modeling material to produce porous scaffolds, made of layers of directionally aligned microfilaments, using this computer-controlled extrusion and deposition process. The PCL scaffolds were produced with a range of channel size 160-700 microm, filament diameter 260-370 microm and porosity 48-77%, and regular geometrical honeycomb pores, depending on the processing parameters. The scaffolds of different porosity also exhibited a pattern of compressive stress-strain behavior characteristic of porous solids under such loading. The compressive stiffness ranged from 4 to 77 MPa, yield strength from 0.4 to 3.6 MPa and yield strain from 4% to 28%. Analysis of the measured data shows a high correlation between the scaffold porosity and the compressive properties based on a power-law relationship.

Hydrogels for biomedical applications

This article reviews the composition and synthesis of hydrogels, the character of their absorbed water, and permeation of solutes within their swollen matrices. The most important properties of hydrogels relevant to their biomedical applications are also identified, especially for use of hydrogels as drug and cell carriers, and as tissue engineering matrices.