Supercritical Foaming and Impregnation of Polycaprolactone and Polycaprolactone-Hydroxyapatite Composites with Carvacrol

Polycaprolactone (PCL) and polycaprolactone-hydroxyapatite (PCL-HA) scaffolds were produced by foaming in supercritical carbon dioxide (scCO2) at 20 MPa, as well as in one-step foaming and impregnation process using carvacrol as an antibacterial agent with proven activity against Gram-positive and Gram-negative bacteria. The experimental design was developed to study the influence of temperature (40 °C and 50 °C), HA content (10 and 20 wt.%), and depressurization rate (one and two-step decompression) on the foams’ morphology, porosity, pore size distribution, and carvacrol impregnation yield. The characterization of the foams was carried out using scanning electron microscopy (SEM, SEM-FIB), Gay-Lussac density bottle measurements, and Fourier–transform infrared (FTIR) analyses. The obtained results demonstrate that processing PCL and PCL-HA scaffolds by means of scCO2 foaming enables preparing foams with porosity in the range of 65.55–74.39% and 61.98–67.13%, at 40 °C and 50 °C, respectively. The presence of carvacrol led to a lower porosity. At 40 °C and one-step decompression at a slow rate, the porosity of impregnated scaffolds was higher than at 50 °C and two- step fast decompression. However, a narrower pore size distribution was obtained at the last processing conditions. PCL scaffolds with HA resulted in higher carvacrol impregnation yields than neat PCL foams. The highest carvacrol loading (10.57%) was observed in the scaffold with 10 wt.% HA obtained at 50 °C.

Fabrication, Characterization and In Vitro Assessment of Laevistrombus canarium-Derived Hydroxyapatite Particulate-Filled Polymer Composite for Implant Applications

This paper presents the formulation, characterization, and in vitro studies of polymer composite material impregnated with naturally derived hydroxyapatite (HA) particulates for biomedical implant applications. Laevistrombus canarium (LC) seashells (SS) were collected, washed and cleaned, sun-dried for 24 h, and ground into powder particulates. The SS particulates of different weight percentages (0, 10, 20, 30, 40, 50 wt%)-loaded high-density polyethylene (HDPE) composites were fabricated by compression molding for comparative in vitro assessment. A temperature-controlled compression molding technique was used with the operating pressure of 2 to 3 bars for particulate retention in the HDPE matrix during molding. The HDPE/LC composite was fabricated and characterized using X-ray diffraction (XRD), field-emission scanning electron microscopy (FESEM), energy-dispersive X-ray (EDX), differential scanning calorimetry (DSC), and TGA. Mechanical properties such as tensile, compression, flexural, hardness, and also surface roughness were tested as per ASTM standards. Mass degradation and thermal stability of the HDPE/LC composite were evaluated at different temperatures ranging from 10 to 700 °C using thermogravimetric analysis (TGA). The maximum tensile strength was found to be 27 ± 0.5 MPa for 30 wt% HDPE/LC composite. The thermal energy absorbed during endothermic processes was recorded as 71.24 J/g and the peak melting temperature (Tm) was found to be 128.4 °C for the same 30 wt% of HDPE/LC composite specimen. Excellent cell viability was observed during the in vitro biocompatibility study for EtO-sterilized 30 wt% of HDPE/LC composite specimen, except for a report of mild cytotoxicity in the case of higher concentration (50 µL) of the MG-63 cell line. The results demonstrate the potential of the fabricated composite as a suitable biomaterial for medical implant applications.

Emulsion templated scaffolds of poly(ε-caprolactone) - a review

The role of poly(ε-caprolactone) (PCL) and its 3D scaffolds in tissue engineering has already been established due to its ease of processing into long-term degradable implants and approval from the FDA. This review presents the role of high internal phase emulsion (HIPE) templating in the fabrication of PCL scaffolds, and the versatility of the technique along with challenges associated with it. Considering the huge potential of HIPE templating, which so far has mainly been focused on free radical polymerization of aqueous HIPEs, we provide a summary of how the technique has been expanded to non-aqueous HIPEs and other modes of polymerization such as ring-opening. The scope of coupling of HIPE templating with some of the advanced fabrication methods such as 3D printing or electrospinning is also explored.

Immobilization of BMP-2 and VEGF within Multilayered Polydopamine-Coated Scaffolds and the Resulting Osteogenic and Angiogenic Synergy of Co-Cultured Human Mesenchymal Stem Cells and Human Endothelial Progenitor Cells

We have previously reported the fabrication of a polycaprolactone and hydroxyapatite composite scaffold incorporating growth factors to be used for bone regeneration. Two growth factors were incorporated employing a multilayered coating based on polydopamine (PDA). In particular, Bone morphogenetic protein-2 (BMP-2) was bound onto the inner PDA layer while vascular endothelial growth factor (VEGF) was immobilized onto the outer one. Herein, the in vitro release of both growth factors is evaluated. A fastest VEGF delivery followed by a slow and more sustained release of BMP-2 was demonstrated, thus fitting the needs for bone tissue engineering applications. Due to the relevance of the crosstalk between bone-promoting and vessel-forming cells during bone healing, the functionalized scaffolds are further assessed on a co-culture setup of human mesenchymal stem cells and human endothelial progenitor cells. Osteogenic and angiogenic gene expression analysis indicates a synergistic effect between the growth factor-loaded scaffolds and the co-culture conditions. Taken together, these results indicate that the developed scaffolds hold great potential as an efficient platform for bone-tissue applications.

Development and Characterization of Polyester and Acrylate-Based Composites with Hydroxyapatite and Halloysite Nanotubes for Medical Applications

We aimed to study the distribution of hydroxyapatite (HA) and halloysite nanotubes (HNTs) as fillers and their influence on the hydrophobic character of conventional polymers used in the biomedical field. The hydrophobic polyester poly (ε-caprolactone) (PCL) was blended with its more hydrophilic counterpart poly (lactic acid) (PLA) and the hydrophilic acrylate poly (2-hydroxyethyl methacrylate) (PHEMA) was analogously compared to poly (ethyl methacrylate) (PEMA) and its copolymer. The addition of HA and HNTs clearly improve surface wettability in neat samples (PCL and PHEMA), but not that of the corresponding binary blends. Energy-dispersive X-ray spectroscopy mapping analyses show a homogenous distribution of HA with appropriate Ca/P ratios between 1.3 and 2, even on samples that were incubated for seven days in simulated body fluid, with the exception of PHEMA, which is excessively hydrophilic to promote the deposition of salts on its surface. HNTs promote large aggregates on more hydrophilic polymers. The degradation process of the biodegradable polyester PCL blended with PLA, and the addition of HA and HNTs, provide hydrophilic units and decrease the overall crystallinity of PCL. Consequently, after 12 weeks of incubation in phosphate buffered saline the mass loss increases up to 48% and mechanical properties decrease above 60% compared with the PCL/PLA blend.

Multi-layered polydopamine coatings for the immobilization of growth factors onto highly-interconnected and bimodal PCL/HA-based scaffolds

For bone tissue engineering applications, scaffolds that mimic the porous structure of the extracellular matrix are highly desirable. Herein, we employ a PCL/HA-based scaffold with a double-scaled architecture of small pores coupled to larger ones. To improve the osteoinductivity of the scaffold, we incorporate two different growth factors via polydopamine (PDA) coating. As a first step, we identify the maximum amount of PDA that can be deposited onto the scaffold. Next, to allow for the deposition of a second PDA layer which, in turn, will allow to increase the loading of growth factors, we incorporate a dithiol connecting layer. The thiol groups covalently react with the first PDA coating through Michael addition while also allowing for the incorporation of a second PDA layer. We load the first and second PDA layers with bone morphogenic protein-2 (BMP2) and vascular endothelial growth factor (VEGF), respectively, and evaluate the osteogenic potential of the functionalised scaffold by cell viability, alkaline phosphatase activity and the expression of three different osteogenesis-related genes of pre-seeded human mesenchymal stem cells. Through these studies, we demonstrate that the osteogenic activity of the scaffolds loaded with both BMP2 and VEGF is greater than scaffolds loaded only with BMP2. Importantly, the osteoinductivity is higher when the scaffolds are loaded with BMP2 and VEGF in two different PDA layers. Taken together, these results indicate that the as-prepared scaffolds could be a useful construct for bone-tissue applications.

Poly(d,l-Lactic acid) Composite Foams Containing Phosphate Glass Particles Produced via Solid-State Foaming Using CO2 for Bone Tissue Engineering Applications

This study reports on the production and characterization of highly porous (up to 91%) composite foams for potential bone tissue engineering (BTE) applications. A calcium phosphate-based glass particulate (PGP) filler of the formulation 50P₂O₅-40CaO-10TiO₂ mol.%, was incorporated into biodegradable poly(d,l-lactic acid) (PDLLA) at 5, 10, 20, and 30 vol.%. The composites were fabricated by melt compounding (extrusion) and compression molding, and converted into porous structures through solid-state foaming (SSF) using high-pressure gaseous carbon dioxide. The morphological and mechanical properties of neat PDLLA and composites in both nonporous and porous states were examined. Scanning electron microscopy micrographs showed that the PGPs were well dispersed throughout the matrices. The highly porous composite systems exhibited improved compressive strength and Young’s modulus (up to >2-fold) and well-interconnected macropores (up to ~78% open pores at 30 vol.% PGP) compared to those of the neat PDLLA foam. The pore size of the composite foams decreased with increasing PGPs content from an average of 920 µm for neat PDLLA foam to 190 µm for PDLLA-30PGP. Furthermore, the experimental data was in line with the Gibson and Ashby model, and effective microstructural changes were confirmed to occur upon 30 vol.% PGP incorporation. Interestingly, the SSF technique allowed for a high incorporation of bioactive particles (up to 30 vol.%—equivalent to ~46 wt.%) while maintaining the morphological and mechanical criteria required for BTE scaffolds. Based on the results, the SSF technique can offer more advantages and flexibility for designing composite foams with tunable characteristics compared to other methods used for the fabrication of BTE scaffolds.

Foaming Behavior and Microcellular Morphologies of Incompatible SAN/CPE Blends with Supercritical Carbon Dioxide as a Physical Blowing Agent

The foaming process and cellular morphologies of poly(styrene-co-acrylonitrile) (SAN)/chlorinated polyethylene (CPE) blends with supercritical carbon dioxide (scCO₂) as a blowing agent were investigated in this study. As compared to pure SAN foam in the same batch, the foamed blends with various CPE elastomer content had smaller average pore size and larger cell density. This is probably related to the inhibition of bubble growth by elastomer, resulting in poor melt flowability and strong viscoelasticity, and the efficient bubble heterogeneous nucleation caused by numerous phase interfaces inside the incompletely compatible blend system. In addition, many tiny interconnected holes through the pore walls were formed to connect adjacent micropores in foamed blend samples. The formation mechanism of such interconnected pores is probably due to the fracture of stretched melt around the bubble from phase interfaces with weak interactions. These facts suggest an effective path to control pore size, cell density and even interconnected pores of blend foams depends on the compatibility of the blend system and difference in foamability of individual components in supercritical CO₂.

Preparation and mechanical properties of thermosetting epoxy foams based on epoxy/ 2-ethyl-4-methylimidazol system with different curing agent contents

Epoxy/2-ethyl-4-methylimidazol system with different curing agent content was completely cured for foaming, and the effect of a systematic variation in 2-ethyl-4-methylimidazol content on the crosslinking density of cured epoxy resins was investigated. It was found that the crosslinking density of completed cured epoxy reduced as the 2-ethyl-4-methylimidazol content increased in certain range of contents (10–50 mol%). Then the precursors were foamed by a batch foaming process with supercritical carbon dioxide. The cellular morphologies of foamed epoxy resins were analyzed by scanning electron microscopy. The results revealed that the reduced crosslinking density would improve the foamability of cured epoxy resin. The microcellular epoxy foams could be obtained by maintaining a moderate crosslinking density, which can be controlled by varying 2-ethyl-4-methylimidazol content. For the completely cured epoxy with different curing agent content, when the crosslinking density of epoxy resin was 232.40 mol m–3 (the 2-ethyl-4-methylimidazol content was 35 mol%) or lower, microcellular structure was obtained by adjusting the foaming conditions. The effects of foaming on the mechanical properties were also discussed. The results indicated that microcellular epoxy foams had higher impact strength but lower tensile strength and tensile modulus, validating that the introduction of microcellular structure in epoxy matrix was conducive to the improvement of the ductility of epoxy foams.

Microwave synthesis and actuation of shape memory polycaprolactone foams with high speed

Microwave technology is a highly effective approach to fast and uniform heating. This article investigates that the microwave heating as a novel method is used to rapidly foam and actuate biocompatible and biodegradable shape memory crosslinked-polycaprolactone (c-PCL) foams. The optical microscope proves that the resulting c-PCL foams have homogenous pore structure. Mechanical behavior and shape memory performance of c-PCL foams are investigated by static materials testing. Shape recovery ratio is approximately 100% and the whole recovery process takes only 98 s when trigged by microwave. Due to the unique principle of microwave heating, the recovery speed of c-PCL foams in microwave oven is several times faster than that in hot water and electric oven. Hence compared to the traditional heating methods, microwave is expected to bring more advantages to modern industry and scientific research in the field of smart materials and structures.

Pickering high internal phase emulsion-based hydroxyapatite-poly(ε-caprolactone) nanocomposite scaffolds

Biocompatible, biodegradable and bioactive nanocomposite (NC) scaffolds with well-defined interconnected porous structures have attracted increasing attention in bone tissue engineering. In this work, we develop a facile method to fabricate poly(l-lactic acid)-modified hydroxyapatite (g-HAp)-poly(ε-caprolactone) (PCL) NC porous scaffolds by solvent evaporation based on water-in-dichloromethane (W/O) Pickering high internal phase emulsion (HIPE) templates, which are stabilized using g-HAp nanoparticles. The resultant porous scaffolds demonstrate interconnected and rough pore structures, which can be adjusted readily by varying g-HAp nanoparticle concentration, PCL concentration and the internal phase volume fraction. Moreover, the investigation of mechanical properties and in vitro biomineralization activity shows that the Young's modulus, compressive stress and bioactivity of the fabricated porous scaffolds are significantly enhanced upon increasing the g-HAp nanoparticle concentration. In addition, in vitro drug release studies of the porous scaffolds using ibuprofen (IBU) as a model drug show that the loaded IBU displays a sustained release profile. In vitro cell culture assays confirm that mouse bone mesenchymal stem cells can adhere, spread, and proliferate on the porous scaffolds, indicating that the porous scaffolds are biocompatible. All these results suggest that the fabricated g-HAp-PCL NC scaffolds have a promising potential for bone tissue engineering application.

Osteogenic poly(ε-caprolactone)/poloxamine homogeneous blends prepared by supercritical foaming

Homogeneous poly(ε-caprolactone) (PCL) and poloxamines (PLXs) porous blends were prepared using a supercritical carbon dioxide-assisted foaming/mixing (SFM) approach aiming to obtain cytocompatible implantable materials presenting tunable morphologies, bioerosion rates, bioactive molecules release and osteogenic features. Pure PCL, pure PLXs (T908 and T1107 varieties) and three distinct PCL:PLX 75:25, 50:50, 25:75% w/w blends, with and without the osteogenic and angiogenic bioactive molecule simvastatin were processed at constant pressure of 20 MPa and temperature of 40 °C or 43 °C, for T1107 and T908, respectively. Obtained porous blends were characterized applying a wide range of techniques and in vitro methods. Calorimetric analysis showed that hydrophilic T908 and T1107 PLXs are miscible with PCL for all tested compositions. Prepared PCL:PLX porous blends rapidly lost mass when immersed into phosphate buffer pH 7.4 due to PLXs dissolution and then went through slow and almost constant erosion rates for the subsequent weeks due to PCL slow hydrolytic degradation, which explains the rapid initial release of simvastatin and its subsequent sustained release for longer periods of time. PCL and PCL:PLX 75:25% w/w porous blends, containing or not simvastatin, showed a high cytocompatibility with SAOS-2 cells. In addition, prepared biomaterials promoted mesenchymal stem cells proliferation and their differentiation into osteoblasts. Overall, obtained results showed novel possibilities of addressing local treatment of small bone defects/fractures using highly porous PCL:PLX homogeneous blends.

Fabrication of porous synthetic polymer scaffolds for tissue engineering

Tissue engineering provides a novel and promising approach to replace damaged tissue with an artificial substitute. Porous synthetic biodegradable polymers are the preferred materials for this substitution due to their microstructure, biocompatibility, biodegradability, and low cost. As a crucial element in tissue engineering, a scaffold acts as an artificial extracellular matrix (ECM) and provides support for cell migration, differentiation, and reproduction. The fabrication of viable scaffolds, however, has been a challenge in both clinical and academic settings. Methods such as solvent casting/particle leaching, thermally induced phase separation (TIPS), electrospinning, gas foaming, and rapid prototyping (additive manufacturing) have been developed or introduced for scaffold fabrication. Each method has its own advantages and disadvantages. In this review, the commonly used synthetic polymer scaffold fabrication methods will be introduced and discussed in detail, and recent progress regarding scaffold fabrication—such as combining different scaffold fabrication methods, combining various materials, and improving current scaffold fabrication methods—will be reviewed as well.

Morphology, mechanical properties, and shape memory effects of poly(lactic acid)/ thermoplastic polyurethane blend scaffolds prepared by thermally induced phase separation

Novel blended scaffolds combining biobased polylactic acid (PLA) and thermoplastic polyurethane (TPU) were fabricated by thermally induced phase separation (TIPS) using two different solvents. Pure PLA and TPU polymer scaffolds using 1,4-dioxane as the sole solvent exhibited typical ladder-like structures, while blended PLA/TPU scaffolds using the same solvent showed a more uniform microstructure. When de-ionized water was added to the solution as a non-solvent, scaffolds with the mixed solvent showed more open cells and greater interconnectivity. In compression tests, it was found that specimens, including pure PLA, TPU, and blended scaffolds with the mixed solvent, showed a higher compressive modulus than their counterparts that used dioxane as the single solvent. Dynamic mechanical analysis (DMA) was employed to characterize the shape memory properties of the scaffolds. DMA indicated that the shape fixing ratio was highest in the PLA scaffolds, while the shape recovery ratio of the TPU scaffolds was the greatest among the specimens. More interestingly, when the mixed solvent was used, the shape memory property of the blended scaffolds displayed a similar deformation curve to the TPU scaffold. This was due to the presence of the TPU phase and similarity in structure between PLA/TPU and TPU scaffolds when mixed solvent was used. In the degradation test, the blended scaffolds showed a balanced degradation behavior in-between the more easily degraded PLA and the more stable TPU in the phosphate-buffered saline (PBS), and the addition of water to the systems accelerated the degradation process of the specimens. Cell culture results showed that all of the scaffolds had good biocompatibility.

Retracted Article: Polycaprolactone composites with TiO2 for potential nanobiomaterials: tunable properties using different phases

TiO₂ nanoparticles of different phases play a key role in property alteration of nanocomposite fibers.