A novel thermoplastic polyurethane scaffold fabrication method based on injection foaming with water and supercritical carbon dioxide as coblowing agents

Investigation into the effects of foaming variables on the cellular structure and expansion ratio of foamed TPU using response surface methodology

Thermoplastic polyurethane elastomer (TPU) foams were prepared using the high-pressure autoclave with supercritical fluid carbon dioxide (SC-CO2). The effects of foaming variables (i.e. saturation temperature, saturation pressure, and depressurization rate) on cellular structure and expansion ratio were investigated. The model between expansion ratio and foaming variables was constructed using the Box-Behnken design (BBD) of response surface methodology (RSM), and analysis of variance (ANOVA) was conducted to evaluate the validity and significance of the model. Finally, the interactive effects of foaming variables on the expansion ratio were investigated, and the expansion ratios of maximum and center point from numerical model were verified by experiment. The result showed higher saturation pressure and depressurization rate resulted in the more uniform cellular structure and higher cell density, however the higher saturation temperature resulted in the bigger cell and nonuniform structure. The ranges of average cell diameter and cell density were 15.26–45.4 μm and 0.32 × 108 to 6.24 × 108 cells/cm3, respectively. The model obtained using BBD of RSM was valid to predict the expansion ratio in the design window. The saturation temperature was the most important factor influencing the expansion ratio. With the increase of saturation temperature, the expansion ratio always increases in the design window. The maximum expansion ratio from numerical optimization was 4.91, which was located at saturation temperature 190°C, saturation pressure 12.51 MPa, and depressurization rate 5 MPa/s, and the corresponding experiment value was 4.56. The error between them was 7.13%.

Recent Advancements in Polyurethane-based Tissue Engineering

In tissue engineering, polyurethane-based implants have gained significant traction because of their high compatibility and inertness. The implants therefore show fewer side effects and lasts longer. Also, the mechanical properties can be tuned and morphed into a particular shape, owing to which polyurethanes show immense versatility. In the last 3 years, scientists have devised methods to enhance the strength of and induce dynamic properties in polyurethanes, and these developments offer an immense opportunity to use them in tissue engineering. The focus of this review is on applications of polyurethane implants for biomedical application with detailed analysis of hard tissue implants like bone tissues and soft tissues like cartilage, muscles, skeletal tissues, and blood vessels. The synthetic routes for the preparation of scaffolds have been discussed to gain a better understanding of the issues that arise regarding toxicity. The focus here is also on concerns regarding the biocompatibility of the implants, given that the precursors and byproducts are poisonous.

Development of Porous Polyurethane Implants Manufactured via Hot-Melt Extrusion

Implantable drug delivery systems (IDDSs) offer good patient compliance and allow the controlled delivery of drugs over prolonged times. However, their application is limited due to the scarce material selection and the limited technological possibilities to achieve extended drug release. Porous structures are an alternative strategy that can overcome these shortcomings. The present work focuses on the development of porous IDDS based on hydrophilic (HPL) and hydrophobic (HPB) polyurethanes and chemical pore formers (PFs) manufactured by hot-melt extrusion. Different PF types and concentrations were investigated to gain a sound understanding in terms of extrudate density, porosity, compressive behavior, pore morphology and liquid uptake. Based on the rheological analyses, a stable extrusion process guaranteed porosities of up to 40% using NaHCO3 as PF. The average pore diameter was between 140 and 600 µm and was indirectly proportional to the concentration of PF. The liquid uptake of HPB was determined by the open pores, while for HPL both open and closed pores influenced the uptake. In summary, through the rational selection of the polymer type, the PF type and concentration, porous carrier systems can be produced continuously via extrusion, whose properties can be adapted to the respective application site.

Nano/microstructures of shape memory polymers: from materials to applications

Shape memory polymers (SMPs) are macromolecules in which linear chains and crosslinking points play a key role in providing a shape memory effect. As smart polymers, SMPs have the ability to change shape, stiffness, size, and structure when exposed to external stimuli, leading to potential uses for SMPs throughout our daily lives in a diverse range of areas including the aerospace and automotive industries, robotics, biomedical engineering, smart textiles, and tactile devices. SMPs can be fabricated in many forms and sizes from the nanoscale to the macroscale, including nanofibers, nanoparticles, thin films, microfoams, and bulk devices. The introduction of nanostructure into SMPs can result in enhanced mechanical properties, unique structural color, specific surface area, and multiple functions. It is necessary to enhance the current understanding of the various nano/microstructures of SMPs and their fabrication, and to find suitable approaches for constructing SMP-based nano/microstructures for different applications. In this review, we summarize the current state of different SMP nano/microstructures, fabrication techniques, and applications, and give suggestions for their future development.

Thermoplastic polyurethane foams: From autoclave batch foaming to bead foam extrusion

Two ester-based and one ether-based thermoplastic polyurethane grades have been used to produce thermoplastic polyurethane foams. The foaming process comprised pressure-induced batch foaming, foam extrusion, and bead foam extrusion by using an underwater granulator. Foam density and morphological properties, such as cell size, cell size distribution, and cell density, were measured through different analytical methods. Through autoclave batch foaming a minimum cell size of 10 µm and density of 202 kg/m3 is obtained, which is lower than the densities previously reported in the literature for thermoplastic polyurethane. Extrusion foaming however could not achieve the same range of foam expansion given that the lowest density achieved is 635 kg/m3 and a minimum cell size equal to 46 µm. The production of thermoplastic polyurethane bead foams is also reported for the first time. The minimum density of the obtained foamed beads is 306 kg/m3 and the lowest cell size is 55 µm.

Elastic materials for tissue engineering applications: Natural, synthetic, and hybrid polymers

Elastin and collagen are the two main components of elastic tissues and provide the tissue with elasticity and mechanical strength, respectively. Whereas collagen is adequately produced in vitro, production of elastin in tissue-engineered constructs is often inadequate when engineering elastic tissues. Therefore, elasticity has to be artificially introduced into tissue-engineered scaffolds. The elasticity of scaffold materials can be attributed to either natural sources, when native elastin or recombinant techniques are used to provide natural polymers, or synthetic sources, when polymers are synthesized. While synthetic elastomers often lack the biocompatibility needed for tissue engineering applications, the production of natural materials in adequate amounts or with proper mechanical strength remains a challenge. However, combining natural and synthetic materials to create hybrid components could overcome these issues. This review explains the synthesis, mechanical properties, and structure of native elastin as well as the theories on how this extracellular matrix component provides elasticity in vivo. Furthermore, current methods, ranging from proteins and synthetic polymers to hybrid structures that are being investigated for providing elasticity to tissue engineering constructs, are comprehensively discussed.

STATEMENT OF SIGNIFICANCE

Tissue engineered scaffolds are being developed as treatment options for malfunctioning tissues throughout the body. It is essential that the scaffold is a close mimic of the native tissue with regards to both mechanical and biological functionalities. Therefore, the production of elastic scaffolds is of key importance to fabricate tissue engineered scaffolds of the elastic tissues such as heart valves and blood vessels. Combining naturally derived and synthetic materials to reach this goal proves to be an interesting area where a highly tunable material that unites mechanical and biological functionalities can be obtained.