Microcellular open porous monoliths for cell growth by thiol-ene polymerization of low-toxicity monomers in high internal phase emulsions

Additive and Lithographic Manufacturing of Biomedical Scaffold Structures Using a Versatile Thiol-Ene Photocurable Resin

Additive and lithographic manufacturing technologies using photopolymerisation provide a powerful tool for fabricating multiscale structures, which is especially interesting for biomimetic scaffolds and biointerfaces. However, most resins are tailored to one particular fabrication technology, showing drawbacks for versatile use. Hence, we used a resin based on thiol-ene chemistry, leveraging its numerous advantages such as low oxygen inhibition, minimal shrinkage and high monomer conversion. The resin is tailored to applications in additive and lithographic technologies for future biofabrication where fast curing kinetics in the presence of oxygen are required, namely 3D inkjet printing, digital light processing and nanoimprint lithography. These technologies enable us to fabricate scaffolds over a span of six orders of magnitude with a maximum of 10 mm and a minimum of 150 nm in height, including bioinspired porous structures with controlled architecture, hole-patterned plates and micro/submicro patterned surfaces. Such versatile properties, combined with noncytotoxicity, degradability and the commercial availability of all the components render the resin as a prototyping material for tissue engineers.

Engineering periodontal tissue interfaces using multiphasic scaffolds and membranes for guided bone and tissue regeneration

Periodontal diseases are one of the greatest healthcare burdens worldwide. The periodontal tissue compartment is an anatomical tissue interface formed from the periodontal ligament, gingiva, cementum, and bone. This multifaceted composition makes tissue engineering strategies challenging to develop due to the interface of hard and soft tissues requiring multiphase scaffolds to recreate the native tissue architecture. Multilayer constructs can better mimic tissue interfaces due to the individually tuneable layers. They have different characteristics in each layer, with modulation of mechanical properties, material type, porosity, pore size, morphology, degradation properties, and drug-releasing profile all possible. The greatest challenge of multilayer constructs is to mechanically integrate consecutive layers to avoid delamination, especially when using multiple manufacturing processes. Here, we review the development of multilayer scaffolds that aim to recapitulate native periodontal tissue interfaces in terms of physical, chemical, and biological characteristics. Important properties of multiphasic biodegradable scaffolds are highlighted and summarised, with design requirements, biomaterials, and fabrication methods, as well as post-treatment and drug/growth factor incorporation discussed.

A Review of Multi-Material 3D Printing of Functional Materials via Vat Photopolymerization

Additive manufacturing or 3D printing of materials is a prominent process technology which involves the fabrication of materials layer-by-layer or point-by-point in a subsequent manner. With recent advancements in additive manufacturing, the technology has excited a great potential for extension of simple designs to complex multi-material geometries. Vat photopolymerization is a subdivision of additive manufacturing which possesses many attractive features, including excellent printing resolution, high dimensional accuracy, low-cost manufacturing, and the ability to spatially control the material properties. However, the technology is currently limited by design strategies, material chemistries, and equipment limitations. This review aims to provide readers with a comprehensive comparison of different additive manufacturing technologies along with detailed knowledge on advances in multi-material vat photopolymerization technologies. Furthermore, we describe popular material chemistries both from the past and more recently, along with future prospects to address the material-related limitations of vat photopolymerization. Examples of the impressive multi-material capabilities inspired by nature which are applicable today in multiple areas of life are briefly presented in the applications section. Finally, we describe our point of view on the future prospects of 3D printed multi-material structures as well as on the way forward towards promising further advancements in vat photopolymerization.

Emulsion Templated Porous Poly(thiol-enes): Influence of Photopolymerisation, Emulsion Composition, and Phase Behaviour on the Porous Structure and Morphology

1,6-hexanediol diacrylate (HDDA) or divinyl adipate (DVA) and pentaerythritol tetrakis(3-mercaptopropionate) (TT) were polymerised via a thiol-ene radical initiated photopolymerisation using emulsions with a high volume fraction of internal droplet phase and monomers in the continuous phase as precursors. The porous structure derived from the high internal phase emulsions (HIPEs) followed the precursor emulsion setup resulting in an open porous cellularly structured polymer. Changing the emulsion composition and polymerisation conditions influenced the resulting morphological structure significantly. The investigated factors influencing the polymer monolith morphology were the emulsion phase ratio and surfactant concentration, leading to either interconnected cellular type morphology, bicontinuous porous morphology or a hollow sphere inverted structure of the polymerised monoliths. The samples with interconnected cellular morphology had pore diameters between 4 µm and 10 µm with approx. 1 µm sized interconnecting channels while samples with bicontinuous morphology featured approx. 5 µm wide pores between the polymer domains. The appropriate choice of emulsion composition enabled the preparation of highly porous poly(thiol-enes) with either polyHIPE or bicontinuous morphology. The porosities of the prepared samples followed the emulsion droplet phase share and could reach up to 88%.

Thiol-Ene Cross-linking of Poly(ethylene glycol) within High Internal Phase Emulsions: Degradable Hydrophilic PolyHIPEs for Controlled Drug Release

Macroporous polymer monoliths prepared from high internal phase emulsions (HIPEs) can be found in various biomedical applications. While typically water-in-oil HIPEs are applied for polyHIPE preparation, they are not suitable for hydrophilic polyHIPE preparation. Herein, direct oil-in-water emulsions based on water-soluble poly(ethylene glycol)diacrylate or poly(ethylene glycol)dimethacrylate were developed. Furthermore, the incorporation of a hydrophilic water-miscible thiol, ethoxylated trimethylolpropane tris(3-mercaptopropionate) (ETTMP) was reported for the first time within thiol–ene polyHIPEs. Due to the transparency of the emulsions, rapid curing via photopolymerization was feasible. The average pore diameters of the resulting polyHIPEs ranged between 1.2 and 3.6 μm, and porosity of up to 90% was achieved. The water uptake of the materials reached up to 1000% by weight. Drug loading and release were demonstrated, employing salicylic acid as a model drug. Porous profile and biodegradability add to the usefulness of the material for biomedical applications.

Thiolene- and Polycaprolactone Methacrylate-Based Polymerized High Internal Phase Emulsion (PolyHIPE) Scaffolds for Tissue Engineering

Highly porous emulsion templated polymers (PolyHIPEs) provide a number of potential advantages in the fabrication of scaffolds for tissue engineering and regenerative medicine. Porosity enables cell ingrowth and nutrient diffusion within, as well as waste removal from, the scaffold. The properties offered by emulsion templating alone include the provision of high interconnected porosity, and, in combination with additive manufacturing, the opportunity to introduce controlled multiscale porosity to complex or custom structures. However, the majority of monomer systems reported for PolyHIPE preparation are unsuitable for clinical applications as they are nondegradable. Thiol-ene chemistry is a promising route to produce biodegradable photocurable PolyHIPEs for the fabrication of scaffolds using conventional or additive manufacturing methods; however, relatively little research has been reported on this approach. This study reports the groundwork to fabricate thiol- and polycaprolactone (PCL)-based PolyHIPE materials via a photoinitiated thiolene click reaction. Two different formulations, either three-arm PCL methacrylate (3PCLMA) or four-arm PCL methacrylate (4PCLMA) moieties, were used in the PolyHIPE formulation. Biocompatibility of the PolyHIPEs was investigated using human dermal fibroblasts (HDFs) and human osteosarcoma cell line (MG-63) by DNA quantification assay, and developed PolyHIPEs were shown to be capable of supporting cell attachment and viability.

Fundamentals and Design-Led Synthesis of Emulsion-Templated Porous Materials for Environmental Applications

Emulsion templating is at the forefront of producing a wide array of porous materials that offers interconnected porous structure, easy permeability, homogeneous flow-through, high diffusion rates, convective mass transfer, and direct accessibility to interact with atoms/ions/molecules throughout the exterior and interior of the bulk. These interesting features together with easily available ingredients, facile preparation methods, flexible pore-size tuning protocols, controlled surface modification strategies, good physicochemical and dimensional stability, lightweight, convenient processing and subsequent recovery, superior pollutants remediation/monitoring performance, and decent recyclability underscore the benchmark potential of the emulsion-templated porous materials in large-scale practical environmental applications. To this end, many research breakthroughs in emulsion templating technique witnessed by the recent achievements have been widely unfolded and currently being extensively explored to address many of the environmental challenges. Taking into account the burgeoning progress of the emulsion-templated porous materials in the environmental field, this review article provides a conceptual overview of emulsions and emulsion templating technique, sums up the general procedures to design and fabricate many state-of-the-art emulsion-templated porous materials, and presents a critical overview of their marked momentum in adsorption, separation, disinfection, catalysis/degradation, capture, and sensing of the inorganic, organic and biological contaminants in water and air.

Development of Photocurable Polyacrylate-Based PolyHIPEs and the Study of the Kinetics of Photopolymerization, and of Their Thermal, Mechanical and Hydrocarbon Absorption Properties

This article describes a comprehensive study to obtain polymeric porous materials via a photopolymerization technique, using acrylate-based high internal phase emulsions (HIPEs), as a template. The aim of obtaining these polymers was to use them as hydrocarbon absorbing materials. Kinetics of photopolymerization of the acrylate monomers and of the HIPEs were conducted to optimize the process. The obtained monoliths were characterized by thermal analysis such as differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The morphology and surface area were analyzed by scanning electron microscopy (SEM) and Brunauer-Emmett-Teller (BET) analysis. The compression properties of the materials were determined, as well as their absorption properties of hydrocarbons such as hexane, diesel, toluene and chloroform. The findings show that the acrylate-HIPEs displayed high reactivity photopolymerizing in 20 min. The glass transition temperature of the materials were in the range of 2 to 83 °C, depending on the ratio of acrylates in the photocurable formulation, displaying the characteristic morphology with voids and interconnecting windows. The polyHIPEs exhibited superior properties of absorption of the studied hydrocarbons. The order of capability of absorption was chloroform > toluene > hexane > diesel. The optimum absorbing material was that with trimethylolpropane triacrylate, ethylhexyl acrylate and isobornyl acrylate in a 1:0.9:2.1 ratio, which absorbed 778% of chloroform, 378% of toluene, 306 % of hexane and 236% of diesel.

Porous Polymers from High Internal Phase Emulsions as Scaffolds for Biological Applications

High internal phase emulsions (HIPEs), with densely packed droplets of internal phase and monomers dispersed in the continuous phase, are now an established medium for porous polymer preparation (polyHIPEs). The ability to influence the pore size and interconnectivity, together with the process scalability and a wide spectrum of possible chemistries are important advantages of polyHIPEs. In this review, the focus on the biomedical applications of polyHIPEs is emphasised, in particular the applications of polyHIPEs as scaffolds/supports for biological cell growth, proliferation and tissue (re)generation. An overview of the polyHIPE preparation methodology is given and possibilities of morphology tuning are outlined. In the continuation, polyHIPEs with different chemistries and their interaction with biological systems are described. A further focus is given to combined techniques and advanced applications.

Basic Principles of Emulsion Templating and Its Use as an Emerging Manufacturing Method of Tissue Engineering Scaffolds

Tissue engineering (TE) aims to regenerate critical size defects, which cannot heal naturally, by using highly porous matrices called TE scaffolds made of biocompatible and biodegradable materials. There are various manufacturing techniques commonly used to fabricate TE scaffolds. However, in most cases, they do not provide materials with a highly interconnected pore design. Thus, emulsion templating is a promising and convenient route for the fabrication of matrices with up to 99% porosity and high interconnectivity. These matrices have been used for various application areas for decades. Although this polymer structuring technique is older than TE itself, the use of polymerised internal phase emulsions (PolyHIPEs) in TE is relatively new compared to other scaffold manufacturing techniques. It is likely because it requires a multidisciplinary background including materials science, chemistry and TE although producing emulsion templated scaffolds is practically simple. To date, a number of excellent reviews on emulsion templating have been published by the pioneers in this field in order to explain the chemistry behind this technique and potential areas of use of the emulsion templated structures. This particular review focusses on the key points of how emulsion templated scaffolds can be fabricated for different TE applications. Accordingly, we first explain the basics of emulsion templating and characteristics of PolyHIPE scaffolds. Then, we discuss the role of each ingredient in the emulsion and the impact of the compositional changes and process conditions on the characteristics of PolyHIPEs. Afterward, current fabrication methods of biocompatible PolyHIPE scaffolds and polymerisation routes are detailed, and the functionalisation strategies that can be used to improve the biological activity of PolyHIPE scaffolds are discussed. Finally, the applications of PolyHIPEs on soft and hard TE as well as in vitro models and drug delivery in the literature are summarised.

Preparation of PolyHIPE Scaffolds for 3D Cell Culture and the Application in Cytotoxicity Evaluation of Cigarette Smoke

Polystyrene-based polyHIPE (polymerized high internal phase emulsion) materials were prepared by the copolymerization of styrene and divinylbenzene in the continuous phase of a HIPE. The resultant polyHIPE materials were found to have an open-cellular morphology and high porosity, and the polyHIPE structure could be well adjusted by varying the water/oil (W/O) ratio and the amount of emulsifier in the HIPE. Cell culture results showed that the resultant polyHIPE materials, which exhibited larger voids and connected windows as well as high porosity, could promote cell proliferation on the 3D scaffold. A 3D cell cytotoxicity evaluation system was constructed with the polystyrene-based polyHIPE materials as scaffolds and the cigarette smoke cytotoxicity was evaluated. Results showed that the smoke cytotoxicity against A549 cells is much lower in the 3D cell platform compared to the traditional 2D system, showing the great potential of the polyHIPE scaffolds for 3D cell culture and the cytotoxic evaluation of cigarette smoke.

Bioceramic nanocomposite thiol-acrylate polyHIPE scaffolds for enhanced osteoblastic cell culture in 3D

Emulsion-templated (polyHIPE) scaffolds for bone tissue engineering were produced by photopolymerisation of a mixture of trimethylolpropane tris(3-mercaptopropionate) and dipentaerythritol penta-/hexa-acrylate in the presence of hydroxyapatite (HA) or strontium-modified hydroxyapatite (SrHA) nanoparticles. Porous and permeable polyHIPE materials were produced regardless of the type or incorporation level of the bioceramic, although higher loadings resulted in a larger average pore diameter. Inclusion of HA and SrHA into the scaffolds was confirmed by EDX-SEM, FTIR and XPS and quantified by thermogravimetry. Addition of HA to polyHIPE scaffolds significantly enhanced compressive strength (148-216 kPa) without affecting compressive modulus (2.34-2.58 MPa). The resulting materials were evaluated in vitro as scaffolds for the 3D culture of MG63 osteoblastic cells vs. a commercial 3D cell culture scaffold (Alvetex®). Cells were able to migrate throughout all scaffolds, achieving a high density by the end of the culture period (21 days). The presence of HA and in particular SrHA gave greatly enhanced cell proliferation, as determined by staining of histological sections and total protein assay (Bradford). Furthermore, Von Kossa and Alizarin Red staining demonstrated significant mineralisation from inclusion of bioceramics, even at the earliest time point (day 7). Production of alkaline phosphatase (ALP), an early osteogenic marker, was used to investigate the influence of HA and SrHA on cell function. ALP levels were significantly reduced on HA- and SrHA-modified scaffolds by day 7, which agrees with the observed early onset of mineralisation in the presence of the bioceramics. The presented data support our conclusions that HA and SrHA enhance osteoblastic cell proliferation on polyHIPE scaffolds and promote early mineralisation.

Surface glycopolymer-modified functional macroporous polyHIPE obtained by ATRP for the removal of boron in water

Macroporous polymeric monoliths PHIPE-PGAMA were obtained from polyHIPE with surface modification of PGAMA and used for boron removal.

Multiple-Level Porous Polymer Monoliths with Interconnected Cellular Topology Prepared by Combining Hard Sphere and Emulsion Templating for Use in Bone Tissue Engineering

A combination of hard sphere and high internal phase emulsion templating gives a platform for synthesizing hierarchically porous polymers with a unique topology exhibiting interconnected spherical features on multiple levels. Polymeric spheres are fused by thermal sintering to create a 3D monolithic structure while an emulsion with a high proportion of internal phase and monomers in the continuous phase is added to the voids of the previously constructed monolith. Following polymerization of the emulsion and dissolution of the templating structure, a down-replicating topology is created with a primary level of pores as a result of fused spheres of the 3D monolithic structure, a secondary level of pores resulting from the emulsion's internal phase, and a tertiary level of interconnecting channels. Thiol-ene chemistry with divinyladipate and pentaerythritol tetrakis(3-mercaptopropionate) is used to demonstrate the preparation of a crosslinked polyester with overall porosity close to 90%. Due to multilevel porosity, such materials are interesting for applications in bone tissue engineering, possibly simulating the native sponge like bone structure. Their potential to promote ossteointegration is tested using human bone derived osteoblasts. Material-cell interactions are evaluated and they reveal growth and proliferation of osteoblasts both on surface and in the bulk of the scaffold.

Polyester type polyHIPE scaffolds with an interconnected porous structure for cartilage regeneration

Development of artificial materials for the facilitation of cartilage regeneration remains an important challenge in orthopedic practice. Our study investigates the potential for neocartilage formation within a synthetic polyester scaffold based on the polymerization of high internal phase emulsions. The fabrication of polyHIPE polymer (PHP) was specifically tailored to produce a highly porous (85%) structure with the primary pore size in the range of 50–170 μm for cartilage tissue engineering. The resulting PHP scaffold was proven biocompatible with human articular chondrocytes and viable cells were observed within the materials as evaluated using the Live/Dead assay and histological analysis. Chondrocytes with round nuclei were organized into multicellular layers on the PHP surface and were observed to grow approximately 300 μm into the scaffold interior. The accumulation of collagen type 2 was detected using immunohistochemistry and chondrogenic specific genes were expressed with favorable collagen type 2 to 1 ratio. In addition, PHP samples are biodegradable and their baseline mechanical properties are similar to those of native cartilage, which enhance chondrocyte cell growth and proliferation.

Inverse high internal phase emulsion polymerization (i-HIPE) of GMMA, HEMA and GDMA for the preparation of superporous hydrogels as a tissue engineering scaffold

A series of novel superporous hydrogels for regenerative medicine were prepared by oil-in-water (o/w) or inverse high internal phase emulsion (i-HIPE) copolymerization of glycerol monomethacrylate (GMMA), 2-hydroxy ethyl methacrylate (HEMA) and glycerol dimethacrylate (GDMA) as a cross-linker using a non toxic solvent and a redox initiator system at the physiological temperature (37 °C). The monomer GMMA was synthesized from glycidyl methacrylate (GMA) by an alternative facile method using Amberlyst-15. The described i-HIPEs showed a significantly wider stability window. The polyHIPE hydrogels were characterized by FTIR, BET method for surface area, mercury porosimetry, SEM, DSC, TGA, XRD, compressive strain and strain recovery. The swelling ratio of the hydrogels and their degradation in 0.007 M NaOH and lipase B (Candida antarctica) solutions were determined gravimetrically and the rate of degradation was explained in terms of the molecular structure of the hydrogels. The morphological studies showed that the pore diameter varied between 20 and 30 μm and the pore throats (interconnecting windows) diameter was in the range of 4-8 μm. The described polyHIPE hydrogels were found to have an open cell morphology and interconnected pore architecture, which are important characteristics for scaffold applications. The initial cytotoxicity study performed according to ISO-10993-5 indicated cytocompatibility (97% cell viability) and the subsequent cell seeding and proliferation study exhibited 55-88% cell viability (increased monotonously from GHG-1 to GHG-5), which could be attributed to modulation of the physical and chemical properties of the hydrogels. The described super porous hydrogels are considered as potential candidates for scaffold materials in tissue engineering applications.

3D Printable Biophotopolymers for in Vivo Bone Regeneration

The present study investigated two novel biophotopolymer classes that are chemically based on non-toxic poly (vinyl alcohol). These vinylesters and vinylcarbonates were compared to standard acrylates in vitro on MC3T3-E1 cells and in vivo in a small animal model. In vitro, both vinylester and vinylcarbonate monomers showed about tenfold less cytotoxicity when compared to acrylates (IC₅₀: 2.922 mM and 2.392 mM vs. 0.201 mM) and at least threefold higher alkaline phosphatase activity (17.038 and 18.836 vs. 5.795, measured at [10 mM]). In vivo, polymerized 3D cellular structures were implanted into the distal femoral condyle of 16 New Zealand White Rabbits and were observed for periods from 4 to 12 weeks. New bone formation and bone to implant contact was evaluated by histomorphometry at end of observation. Vinylesters showed similar rates of new bone formation but significantly less (p = 0.002) bone to implant contact, when compared to acrylates. In contrast, the implantation of vinylcarbonate based biophotopolymers led to significantly higher rates of newly formed bone (p < 0.001) and bone to implant contact (p < 0.001). Additionally, distinct signs of polymer degradation could be observed in vinylesters and vinylcarbonates by histology. We conclude, that vinylesters and vinylcarbonates are promising new biophotopolymers, that outmatch available poly(lactic acid) and (meth)acrylate based materials.

Preparation of hybrid thiol-acrylate emulsion-templated porous polymers by interfacial copolymerization of high internal phase emulsions

Emulsion-templated highly porous polymers (polyHIPEs), containing distinct regions differing in composition, morphology, and/or properties, are prepared by the simultaneous polymerization of two high internal phase emulsions (HIPEs) contained within the same mould. The HIPEs are placed together in the mould and subjected to thiol-acrylate photopolymerization. The resulting polyHIPE material is found to contain two distinct semicircular regions, reflecting the composition of each HIPE. The original interface between the two emulsions becomes a copolymerized band between 100 and 300 μm wide, which is found to be mechanically robust. The separate polyHIPE layers are distinguished from one another by their differing average void diameter, chemical composition, and extent of contraction upon drying.