The effect of processing variables on morphological and mechanical properties of supercritical CO2 foamed scaffolds for tissue engineering

Green Foaming of Biologically Extracted Chitin Hydrogels Using Supercritical Carbon Dioxide for Scaffolding of Human Osteoblasts

Chitin is a structural polysaccharide abundant in the biosphere. Chitin possesses a highly ordered crystalline structure that makes its processing a challenge. In this study, chitin hydrogels and methanogels, prepared by dissolution in calcium chloride/methanol, were subjected to supercritical carbon dioxide (scCO2) to produce porous materials for use as scaffolds for osteoblasts. The control of the morphology, porosity, and physicochemical properties of the produced materials was performed according to the operational conditions, as well as the co-solvent addition. The dissolution of CO2 in methanol co-solvent improved the sorption of the compressed fluid into the hydrogel, rendering highly porous chitin scaffolds. The chitin crystallinity index significantly decreased after processing the hydrogel in supercritical conditions, with a significant effect on its swelling capacity. The use of scCO2 with methanol co-solvent resulted in chitin scaffolds with characteristics adequate to the adhesion and proliferation of osteoblasts.

Supercritical Impregnation of PETG with Olea europaea Leaf Extract: Influence of Operational Parameters on Expansion Degree, Antioxidant and Mechanical Properties

PETG (poly(ethylene glycol-co-cyclohexane-1,4-dimethanol terephthalate)) is an amorphous copolymer, biocompatible, recyclable, and versatile. Nowadays, it is being actively researched for biomedical applications. However, proposals of PETG as a platform for the loading of bioactive compounds from natural extract are scarce, as well as the effect of the supercritical impregnation on this polymer. In this work, the supercritical impregnation of PETG filaments with Olea europaea leaf extract was investigated, evaluating the effect of pressure (100-400 bar), temperature (35-55 °C), and depressurization rate (5-50 bar min-1) on the expansion degree, antioxidant activity, and mechanical properties of the resulting filaments. PETG expansion degree ranged from ~3 to 120%, with antioxidant loading ranging from 2.28 to 17.96 g per 100 g of polymer, corresponding to oxidation inhibition values of 7.65 and 66.55%, respectively. The temperature and the binary interaction between pressure and depressurization rate most affected these properties. The mechanical properties of PETG filaments depended greatly on process variables. Tensile strength values were similar or lower than the untreated filaments. Young's modulus and elongation at break values decreased below ~1000 MPa and ~10%, respectively, after the scCO2 treatment and impregnation. The extent of this decrease depended on the supercritical operational parameters. Therefore, filaments with higher antioxidant activity and different expansion degrees and mechanical properties were obtained by adjusting the supercritical processing conditions.

Current Trend and New Opportunities for Multifunctional Bio-Scaffold Fabrication via High-Pressure Foaming

Biocompatible and biodegradable foams prepared using the high-pressure foaming technique have been widely investigated in recent decades as porous scaffolds for in vitro and in vivo tissue growth. In fact, the foaming process can operate at low temperatures to load bioactive molecules and cells within the pores of the scaffold, while the density and pore architecture, and, hence, properties of the scaffold, can be finely modulated by the proper selection of materials and processing conditions. Most importantly, the high-pressure foaming of polymers is an ideal choice to limit and/or avoid the use of cytotoxic and tissue-toxic compounds during scaffold preparation. The aim of this review is to provide the reader with the state of the art and current trend in the high-pressure foaming of biomedical polymers and composites towards the design and fabrication of multifunctional scaffolds for tissue engineering. This manuscript describes the application of the gas foaming process for bio-scaffold design and fabrication and highlights some of the most interesting results on: (1) the engineering of porous scaffolds featuring biomimetic porosity to guide cell behavior and to mimic the hierarchical architecture of complex tissues, such as bone; (2) the bioactivation of the scaffolds through the incorporation of inorganic fillers and drugs.

Formation of PLGA-PEDOT: PSS Conductive Scaffolds by Supercritical Foaming

The usage of conjugated materials for the fabrication of foams intended to be used as therapeutic scaffolds is gaining relevance these days, as they hold certain properties that are not exhibited by other polymer types that have been regularly used until the present. Hence, this work aims to design a specific supercritical CO₂ foaming process that would allow the production of porous polymeric devices with improved conductive properties, which would better simulate matrix extracellular conditions when used as therapeutic scaffolds (PLGA-PEDOT:PSS) systems. The effects of pressure, temperature, and contact time on the expansion factor, porosity, mechanical properties, and conductivity of the foam have been evaluated. The foams have been characterized by scanning electron and atomic force microscopies, liquid displacement, PBS degradation test, compression, and resistance to conductivity techniques. Values close to 40% porosity were obtained, with a uniform distribution of polymers on the surface and in the interior, expansion factors of up to 10 orders, and a wide range of conductivity values (2.2 × 10^-7 to 1.0 × 10^-5 S/cm) and mechanical properties (0.8 to 13.6 MPa Young's modulus in compression test). The conductive and porous scaffolds that have been produced by supercritical CO₂ in this study show an interesting potential for tissue engineering and for neural or cardiac tissue regeneration purposes due to the fact that electrical conductivity is a crucial factor for proper cell function and tissue development.

Production and Application of Polymer Foams Employing Supercritical Carbon Dioxide

Polymeric foams have characteristics that make them attractive for different applications. However, some foaming methods rely on chemicals that are not environmentally friendly. One of the possibilities to tackle the environmental issue is to utilize supercritical carbon dioxide ScCO2 since it is a “green” solvent, thus facilitating a sustainable method of producing foams. ScCO2 is nontoxic, chemically inert, and soluble in molten plastic. It can act as a plasticizer, decreasing the viscosity of polymers according to temperature and pressure. Most foam processes can benefit from ScCO2 since the methods rely on nucleation, growth, and expansion mechanisms. Process considerations such as pretreatment, temperature, pressure, pressure drop, and diffusion time are relevant parameters for foaming. Other variables such as additives, fillers, and chain extenders also play a role in the foaming process. This review highlights the morphology, performance, and features of the foam produced with ScCO2, considering relevant aspects of replacing or introducing a novel foam. Recent findings related to foaming assisted by ScCO2 and how processing parameters influence the foam product are addressed. In addition, we discuss possible applications where foams have significant benefits. This review shows the recent progress and possibilities of ScCO2 in processing polymer foams.

Foaming of PCL-Based Composites Using scCO2—Biocompatibility and Evaluation for Biomedical Applications

The process of foaming poly(caprolactone)-based composite materials using supercritical carbon dioxide was analyzed, especially in terms of the biocompatibility of the resultant materials. The influence of foaming process conditions and composite material properties on the functional properties of polymer solid foams, intended for artificial scaffolds for bone cell culture, was investigated. The relationship between wettability (contact angle) and water absorption rate as a result of the application of variable conditions for the production of porous structures was presented. For the evaluation of potential cytotoxicity, the MTT and PrestoBlue tests were carried out, and animal cells (mouse fibroblasts) were cultured on the materials for nine days. There was no toxic effect of composite materials made of poly(caprolactone) containing porogen particles: hydroxyapatite, crystalline nanocellulose, and graphene oxide on cells. The desired effect of the porogens used in the foaming process on the affinity of cells to the resultant material was demonstrated. The tested materials have been shown to be biocompatible and suitable for applications in biomedical engineering.

Development of Porous Polyvinyl Acetate/Polypyrrole/Gallic Acid Scaffolds Using Supercritical CO2 as Tissue Regenerative Agents

Scaffolds are advanced devices employed in tissue engineering, as they are intended to mimic the characteristics of extracellular matrices. In this respect, conjugated materials are gaining relevance in the manufacturing of the foams used for therapeutic scaffolds, since they can provide certain properties that are missing in the other polymers used to form the scaffolds. This work has, therefore, focused on the development of functional scaffolds formed by conjugated-non-conjugated polymers such as polyvinyl acetate and polypyrrole, impregnated with gallic acid as the model drug and produced by means of a supercritical CO₂ foaming/impregnation process. The effects from a series of parameters such as pressure, temperature, depressurization rate, and contact time of the scaffold production process have been determined. The impregnated foams have been characterized according to their morphology, including their porosity and expansion factor, their drug loading and delivering capabilities, and their mechanical and electrical properties. The characterization of the experiments was carried out using scanning electron microscopy, liquid displacement, in vitro release, electrochemical impedance spectroscopy, and compression techniques. The results from our tests have revealed a considerable influence of all the input variables studied, as well as relevant interactions between them. Values close to 35% porosity were obtained, with a drug release of up to 10 h with a fast initial release. The best operating conditions were 353 K, 30 MPa, 0.5 MPa/min depressurization rate, and 1 h contact time. By means of the supercritical foaming/impregnation technique, scaffolds with potential in tissue engineering due to their studied properties were obtained.

Foaming of PCL-Based Composites Using scCO2: Structure and Physical Properties

The process of foaming poly(caprolactone)-based composites using supercritical carbon dioxide was analyzed. The impact of the conditions of the solid-foam production process on the process efficiency and properties of porous structures was investigated. The novel application of various types of porogens—hydroxyapatite, nanocellulose, carboxymethylcellulose, and graphene oxide—was tested in order to modify the properties and improve the quality of solid foams, increasing their usefulness in specialized practical applications. The study showed a significant influence of the foaming process conditions on the properties of solid foams. The optimal process parameters were determined to be pressure 18 MPa, temperature 70 °C, and time 1 h in order to obtain structures with appropriate properties for applications in biomedical engineering, and the most promising material for their production was selected: a composite containing 5% hydroxyapatite or 0.2% graphene oxide.

An Attempt to Optimize Supercritical CO2 Polyaniline-Polycaprolactone Foaming Processes to Produce Tissue Engineering Scaffolds

Conjugated polymers are biomaterials with high conductivity characteristics because of their molecular composition. However, they are too rigid and brittle for medical applications and therefore need to be combined with non-conductive polymers to overcome or lessen these drawbacks. This work has, consequently, focused on the development of three-dimensional scaffolds where conductive and non-conductive polymers have been produced by combining polycaprolactone (PCL) and polyaniline (PANI) by means of supercritical CO2 foaming techniques. To evaluate their therapeutic potential as implants, a series of experiments have been designed to determine the most influential variables in the production of the three-dimensional scaffolds, including temperature, pressure, polymer ratio and depressurization rate. Internal morphology, porosity, expansion factor, PANI loads, biodegradability, mechanical and electrical properties have been taken as the response variables. The results revealed a strong influence from all the input variables studied, as well as from their interactions. The best operating conditions tested were 70 °C, 100 bar, a ratio of 5:1 (PCL:PANI), a depressurization rate of 20 bar/min and a contact time of 1 h.

Polylactide, Processed by a Foaming Method Using Compressed Freon R134a, for Tissue Engineering

Fabricating polymeric scaffolds using cost-effective manufacturing processes is still challenging. Gas foaming techniques using supercritical carbon dioxide (scCO₂) have attracted attention for producing synthetic polymer matrices; however, the high-pressure requirements are often a technological barrier for its widespread use. Compressed 1,1,1,2-tetrafluoroethane, known as Freon R134a, offers advantages over CO₂ in manufacturing processes in terms of lower pressure and temperature conditions and the use of low-cost equipment. Here, we report for the first time the use of Freon R134a for generating porous polymer matrices, specifically polylactide (PLA). PLA scaffolds processed with Freon R134a exhibited larger pore sizes, and total porosity, and appropriate mechanical properties compared with those achieved by scCO₂ processing. PLGA scaffolds processed with Freon R134a were highly porous and showed a relatively fragile structure. Human mesenchymal stem cells (MSCs) attached to PLA scaffolds processed with Freon R134a, and their metabolic activity increased during culturing. In addition, MSCs displayed spread morphology on the PLA scaffolds processed with Freon R134a, with a well-organized actin cytoskeleton and a dense matrix of fibronectin fibrils. Functionalization of Freon R134a-processed PLA scaffolds with protein nanoparticles, used as bioactive factors, enhanced the scaffolds' cytocompatibility. These findings indicate that gas foaming using compressed Freon R134a could represent a cost-effective and environmentally friendly fabrication technology to produce polymeric scaffolds for tissue engineering approaches.

Speckle-Based Sensing of Microscopic Dynamics in Expanding Polymer Foams: Application of the Stacked Speckle History Technique

Microscopic structural rearrangements in expanding polylactide foams were probed using multiple dynamic scattering of laser radiation in the foam volume. Formation and subsequent expansion of polylactide foams was provided by a rapid or slow depressurization of the "plasticized polylactide-supercritical carbon dioxide" system. Dynamic speckles induced by a multiple scattering of laser radiation in the expanding foam were analyzed using the stacked speckle history technique, which is based on a joint mapping of spatial-temporal dynamics of evolving speckle patterns. A significant decrease in the depressurization rate in the case of transition from a rapid to slow foaming (from 0.03 MPa/s to 0.006 MPa/s) causes dramatic changes in the texture of the synthesized stacked speckle history maps. These changes are associated with transition from the boiling dynamics of time-varying speckles to their pronounced translational motions and are manifested as significant slopes of individual speckle traces on the recovered stacked speckle history maps. This feature is interpreted in terms of the actual absence of a new cell nucleation effect in the expanding foam upon slow depressurization on the dynamic scattering of laser radiation.

Colonization versus encapsulation in cell-laden materials design: porosity and process biocompatibility determine cellularization pathways

Seeding materials with living cells has been-and still is-one of the most promising approaches to reproduce the complexity and the functionality of living matter. The strategies to associate living cells with materials are limited to cell encapsulation and colonization, however, the requirements for these two approaches have been seldom discussed systematically. Here we propose a simple two-dimensional map based on materials' pore size and the cytocompatibility of their fabrication process to draw, for the first time, a guide to building cellularized materials. We believe this approach may serve as a straightforward guideline to design new, more relevant materials, able to seize the complexity and the function of biological materials. This article is part of the theme issue 'Bio-derived and bioinspired sustainable advanced materials for emerging technologies (part 1)'.

Supercritical CO2 technology for one-pot foaming and sterilization of polymeric scaffolds for bone regeneration

Sterilization is a quite challenging step in the development of novel polymeric scaffolds for regenerative medicine since conventional sterilization techniques may significantly alter their morphological and physicochemical properties. Supercritical (sc) sterilization, i.e. the use of scCO₂ as a sterilizing agent, emerges as a promising sterilization method due to the mild operational conditions and excellent penetration capability. In this work, a scCO₂ protocol was implemented for the one-pot preparation and sterilization of poly(ε-caprolactone) (PCL)/poly(lactic-co-glycolic acid) (PLGA) scaffolds. The sterilization conditions were established after screening against both Gram-positive (Staphylococcus aureus) and Gram-negative (Escherichia coli, Pseudomonas aeruginosa) vegetative bacteria and spores of Bacillus stearothermophilus, Bacillus pumilus and Bacillus atrophaeus. The transition from the sterilization conditions (140 bar, 39 °C) to the compressed foaming (60 bar, 26 °C) was performed through controlled depressurization (3.2 bar/min) and CO₂ liquid flow. Controlled depressurization/pressurization cycles were subsequently applied. Using this scCO₂ technology toolbox, sterile scaffolds of well-controlled pore architecture were obtained. This sterilization procedure successfully achieved not only SAL-6 against well-known resistant bacteria endospores but also improved the scaffold morphologies compared to standard gamma radiation sterilization procedures.

Propolis loaded and genipin-crosslinked PVA/chitosan membranes; characterization properties and cytocompatibility/genotoxicity response for wound dressing applications

Loading propolis by a simple process using genipin as a crosslinking agent and fabrication of a novel PVA/Chitosan-Propolis membrane scaffolds were reported for wound dressing applications. The research is focused on the effects of propolis on characterization properties of membrane such as chemical structure, surface morphology, degradation ratio, crystallinity, hydrophilicity, water uptake capacity, water vapour transmission rate and mechanical aspect. It was noticed that water uptake capacity and hydrophilicity properties of membrane considerably affected by the propolis. By addition of (0.50, % v/v) propolis, the contact angle of the PVA/Chitosan membrane was remarkably decreased from 86.29° ± 3 to 45 ± 2°. 3-(4,5-dimethylthiazoyl-2-yl)-2,5-diphenylte-trazolium (MTT) bromide test and SEM were used to analyse the cytocompatibility of the membranes and morphology of cells on membrane. The propolis incorporated membrane showed cell proliferation rate 176 ± 13%, 775 ± 1%, and 853 ± 23%, at 24 h, 27 h and 120 h, respectively. SEM images also supported the cell behaviour on membrane. DNA fragmentation was also investigated with genotoxicity test. The studies on the interactions between membranes and MEF cells revealed that the incorporation of propolis into membrane promoted cell proliferation. These overall results presented that propolis incorporated membranes could have potentially appealing application as scaffolds for wound healing applications.

Depressurization-Induced Nucleation in the "Polylactide-Carbon Dioxide" System: Self-Similarity of the Bubble Embryos Expansion

Self-similar expansion of bubble embryos in a plasticized polymer under quasi-isothermal depressurization is examined using the experimental data on expansion rates of embryos in the CO₂-plasticized d,l-polylactide and modeling the results. The CO₂ initial pressure varied from 5 to 14 MPa, and the depressurization rate was 5 × 10⁻³ MPa/s. The constant temperature in experiments was in a range from 310 to 338 K. The initial rate of embryos expansion varied from ≈0.1 to ≈10 µm/s, with a decrease in the current external pressure. While modeling, a non-linear behavior of CO₂ isotherms near the critical point was taken into account. The modeled data agree satisfactorily with the experimental results. The effect of a remarkable increase in the expansion rate at a decreasing external pressure is interpreted in terms of competing effects, including a decrease in the internal pressure, an increase in the polymer viscosity, and an increase in the embryo radius at the time of embryo formation. The vanishing probability of finding the steadily expanding embryos for external pressures around the CO₂ critical pressure is interpreted in terms of a joint influence of the quasi-adiabatic cooling and high compressibility of CO₂ in the embryos.

Solvent-Free Processing of Drug-Loaded Poly(ε-Caprolactone) Scaffolds with Tunable Macroporosity by Combination of Supercritical Foaming and Thermal Porogen Leaching

Demand of scaffolds for hard tissue repair increases due to a higher incidence of fractures related to accidents and bone-diseases that are linked to the ageing of the population. Namely, scaffolds loaded with bioactive agents can facilitate the bone repair by favoring the bone integration and avoiding post-grafting complications. Supercritical (sc-)foaming technology emerges as a unique solvent-free approach for the processing of drug-loadenu7d scaffolds at high incorporation yields. In this work, medicated poly(ε-caprolactone) (PCL) scaffolds were prepared by sc-foaming coupled with a leaching process to overcome problems of pore size tuning of the sc-foaming technique. The removal of the solid porogen (BA, ammonium bicarbonate) was carried out by a thermal leaching taking place at 37 °C and in the absence of solvents for the first time. Macroporous scaffolds with dual porosity (50-100 µm and 200-400 µm ranges) were obtained and with a porous structure directly dependent on the porogen content used. The processing of ketoprofen-loaded scaffolds using BA porogen resulted in drug loading yields close to 100% and influenced its release profile from the PCL matrix to a relevant clinical scenario. A novel solvent-free strategy has been set to integrate the incorporation of solid porogens in the sc-foaming of medicated scaffolds.

Asymmetric Sc-PLA Membrane with Multi-scale Microstructures: Wettability, Antifouling, and Oil-Water Separation

In this work, an eco-friendly superhydrophobic stereo-complex polylactic acid (Sc-PLA) membrane was fabricated by a facile non-solvent-induced phase separation (NIPS) method, followed by peeling off its skin layer. By adjusting the thickness and roughness, membranes with various multi-scale microstructures could be obtained due to the formation of stereo-complex crystals during the process of phase separation. The Sc-PLA membranes display a hydrophobic wetting property. Interestingly, when the skin layer of the membrane with a 600 μm thickness was peeled off, the water contact angle on the surface of the membrane significantly improved from 142 to 152°, and the membrane displayed superhydrophobic wetting properties, which may be owing to the improvement of roughness for the surface by enlarging the exposure opportunity of finger holes and microstructures. In addition, the Sc-PLA membrane with superhydrophobicity shows excellent antifouling performance and large oil absorption capacity. Predictably, the Sc-PLA membranes may have potential applications in antifouling and oil-water separation.

Compostable, fully biobased foams using PLA and micro cellulose for zero energy buildings

Ecological, health and environmental concerns are driving the need for bio-resourced foams for the building industry. In this paper, we examine foams made from polylactic acid (PLA) and micro cellulose fibrils (MCF). To ensure no volatile organic compounds in the foam, supercritical CO₂ (sc-CO₂) physical foaming of melt mixed systems was conducted. Mechanical and thermal conductivity properties were determined and applied to a net zero energy model house. The results showed that MCF had a concentration dependent impact on the foams. First structurally, the presence of MCF led to an initial increase followed by a decrease of open porosity, higher bulk density, lower expansion ratios and cell size. Differential Scanning Calorimetry and Scanning Electron Microscopy revealed that MCF decreased the glass transition of PLA allowing for a decrease in cell wall thickness when MCF was added. The mechanical performance initially increased with MCF and then decreased. This trend was mimicked by thermal insulation which initially improved. Biodegradation tests showed that the presence of cellulose in PLA improved the compostability of the foams. A maximum comparative mineralization of 95% was obtained for the PLA foam with 3 wt.% MCF when expressed as a fractional percentage of the pure cellulose reference. Energy simulations run on a model house showed that relative to an insulation of polyurethane, the bio-resourced foams led to no more than a 12% increase in heating and cooling. The energy efficiency of the foams was best at low MCF fractions.

Colloidal systems toward 3D cell culture scaffolds

Three-dimensional porous scaffolds are essential for the development of tissue engineering and regeneration, as biomimetic supports to recreate the microenvironment present in natural tissues. To successfully achieve the growth and development of a specific kind of tissue, porous matrices should be able to influence cell behavior by promoting close cell-cell and cell-matrix interactions. To achieve this goal, the scaffold must fulfil a set of conditions, including ordered interconnected porosity to promote cell diffusion and vascularization, mechanical strength to support the tissue during continuous ingrowth, and biocompatibility to avoid toxicity. Among various building approaches to the construction of porous matrices, selected strategies afford hierarchical scaffolds with such defined properties. The control over porosity, microstructure or morphology, is crucial to the fabrication of high-end, reproducible scaffolds for the target application. In this review, we provide an insight into recent advances toward the colloidal fabrication of hierarchical scaffolds. After identifying the main requirements for scaffolds in biomedical applications, conceptual building processes are introduced. Examples of tissue regeneration applications are provided for different scaffold types, highlighting their versatility and biocompatibility. We finally provide a prospect about the current state of the art and limitations of porous scaffolds, along with challenges that are to be addressed, so these materials consolidate in the fields of tissue engineering and drug delivery.

Extreme Foaming Modes for SCF-Plasticized Polylactides: Quasi-Adiabatic and Quasi-Isothermal Foam Expansion

The experimental evidence on depressurization foaming of the amorphous D,L-polylactide, which is plasticized by subcritical (initial pressures below the critical value) or supercritical (initial pressures above the critical value) carbon dioxide at a temperature above the critical value, relates to two extreme cases: a slow quasi-isothermal foam expansion, and a rapid quasi-adiabatic expansion. Under certain conditions, the quasi-isothermal mode is characterized by the non-monotonic dependencies of the foam volume on the external pressure that are associated with the expansion-to-shrinkage transition. The quasi-adiabatic and quasi-isothermal expansions are characterized by a significant increase in the degree of foam expansion under conditions where the CO₂ initial pressure approaches the critical value. The observed features are interpreted in terms of the energy balance in the foam volume and the phenomenological model based on the equation of the foam state. The expansion-to-shrinkage condition is based on the relationship between the average bubble radius and the pressure derivative of the surface tension for the plasticized polylactide. The maximum expansion ratio of the rapidly foamed polylactide in the vicinity of the critical point is interpreted in terms of the maximum decrement of the specific internal energy of the foaming agent (carbon dioxide) in the course of depressurization.

Preparation of porous materials by selective enzymatic degradation: effect of in vitro degradation and in vivo compatibility

Poly(butylene succinate) (PBS) and poly(lactic acid) (PLA) were melt-blended and formed into a film by hot press forming. The film was selectively degraded by cutinase and proteinase K to form a porous material. The porous materials were characterized with respect to their pore morphology, pore size, porosity and hydrophilicity. The porous materials were investigated in vitro degradation and in vivo compatibility. The results show that the pore size of the prepared porous materials could be controlled by the proportion of PBS and the degradation time. When the PBS composition of PBS/PLA blends was changed from 40 wt% to 50 wt%, the mean pore diameter of the porous materials significantly increased from 6.91 µm to 120 µm, the porosity improved from 81.52% to 96.90%, and the contact angle decreased from 81.08° to 46.56°. In vitro degradation suggests that the PBS-based porous materials have a good corrosion resistance but the PLA-based porous materials have degradability in simulated body fluid. Subcutaneous implantation of the porous materials did not cause intense inflammatory response, which revealed good compatibility. The results of hematoxylin and eosin and Masson's trichrome staining assays demonstrated that the porous materials promote chondrocyte production. Porous materials have great potential in preparing implants for tissue engineering applications.

Fabrication of PCL Scaffolds by Supercritical CO2 Foaming Based on the Combined Effects of Rheological and Crystallization Properties

Polycaprolactone (PCL) scaffolds have recently been developed via efficient and green supercritical carbon dioxide (scCO₂) melt-state foaming. However, previously reported gas-foamed scaffolds sometimes showed insufficient interconnectivity or pore size for tissue engineering. In this study, we have correlated the thermal and rheological properties of PCL scaffolds with their porous morphology by studying four foamed samples with varied molecular weight (MW), and particularly aimed to clarify the required properties for the fabrication of scaffolds with favorable interconnected macropores. DSC and rheological tests indicate that samples show a delayed crystallization and enhanced complex viscosity with the increasing of MW. After foaming, scaffolds (27 kDa in weight-average molecular weight) show a favorable morphology (pore size = 70–180 μm, porosity = 90% and interconnectivity = 96%), where the lowest melt strength favors the generation of interconnected macropore, and the most rapid crystallization provides proper foamability. The scaffolds (27 kDa) also possess the highest Young’s modulus. More importantly, owing to the sufficient room and favorable material transportation provided by highly interconnected macropores, cells onto the optimized scaffolds (27 kDa) perform vigorous proliferation and superior adhesion and ingrowth, indicating its potential for regeneration applications. Furthermore, our findings provide new insights into the morphological control of porous scaffolds fabricated by scCO₂ foaming, and are highly relevant to a broader community that is focusing on polymer foaming.

Using Supercritical Fluid Technology as a Green Alternative During the Preparation of Drug Delivery Systems

Micro- and nano-carrier formulations have been developed as drug delivery systems for active pharmaceutical ingredients (APIs) that suffer from poor physico-chemical, pharmacokinetic, and pharmacodynamic properties. Encapsulating the APIs in such systems can help improve their stability by protecting them from harsh conditions such as light, oxygen, temperature, pH, enzymes, and others. Consequently, the API's dissolution rate and bioavailability are tremendously improved. Conventional techniques used in the production of these drug carrier formulations have several drawbacks, including thermal and chemical stability of the APIs, excessive use of organic solvents, high residual solvent levels, difficult particle size control and distributions, drug loading-related challenges, and time and energy consumption. This review illustrates how supercritical fluid (SCF) technologies can be superior in controlling the morphology of API particles and in the production of drug carriers due to SCF's non-toxic, inert, economical, and environmentally friendly properties. The SCF's advantages, benefits, and various preparation methods are discussed. Drug carrier formulations discussed in this review include microparticles, nanoparticles, polymeric membranes, aerogels, microporous foams, solid lipid nanoparticles, and liposomes.

Foaming of Polycaprolactone and Its Impregnation with Quercetin Using Supercritical CO2

Foamed polycaprolactone impregnated with quercetin was carried out with a batch foaming technique using supercritical CO₂. The experimental design was developed to study the influence of pressure (15–30 MPa), temperature (308–333 K), and depressurization rate (0.1–20) on the foam structure, melting temperature, and release tests of composites. The characterization of the experiments was carried out using scanning electron microscopy, X-ray diffractometer, and differential scanning calorimetry techniques. It was observed that the porosity created in the polymer had a heterogeneous structure, as well as the impregnation of the quercetin during the process. On the other hand, controlled release tests showed a significant delay in the release of quercetin compared to commercial quercetin.

Evaluating the Clinical Impact of Formulation Variability: A Metoprolol Extended-Release Case Study

The objective of this research was to evaluate the impact of changes in the formulation of metoprolol extended-release (ER) tablets on dissolution, pharmacokinetic, and exercise-induced heart rate (EIHR) using a combined physiologically based absorption pharmacokinetic, and population pharmacokinetic/pharmacodynamic modeling and simulation approach. Using a previously developed physiologically based absorption pharmacokinetic model in DDDPlus and GastroPlus, we simulated the changes in drug release and exposure as the result of quantitative changes in the release-controlling excipient, hydroxylpropylmethylcellulose, for 50 and 200 mg. The similarity of dissolution profiles was assessed using the f₂ test, and bioequivalence was tested on the simulated pharmacokinetic profiles. We used the simulated concentration-time profiles following formulation changes as pharmacokinetic input into a population pharmacokinetic/pharmacodynamic model newly developed in NONMEM to determine if changes in pharmacokinetics lead to clinically significant changes in pharmacodynamics. Pharmacodynamic assessment was based on the percentage reduction in the EIHR from baseline. Therapeutic effect was considered similar when the model-predicted EIHR was within 50% to 85% of the average maximum EIHR of healthy 30-year-old subjects. A 40% or more increase in the release rate constant resulted in dissimilarity in dissolution profiles and bioINequivalence in pharmacokinetics for both 50 and 200 mg. Formulation-related differences in drug release of metoprolol ER tablets can lead to differences in pharmacokinetics. However, the evaluated pharmacokinetic differences do not lead to clinically meaningful differences in EIHR, suggesting that EIHR may not be sensitive enough to detect changes in pharmacokinetics of metoprolol ER products.

Preparation of Thermoplastic Polyurethane (TPU) Perforated Membrane via CO2 Foaming and Its Particle Separation Performance

The way in which a perforated structure is formed has attracted much interest in the porous membrane research community. This novel structure gives materials an excellent antifouling property as well as a low operating pressure and other benefits. Unfortunately, the current membrane fabrication methods usually involve multi-step processes and the use of organic solvents or additives. Our study is the first to offer a way to prepare perforated membrane by using a physical foaming technique with CO2 as the blowing agent. We selected thermoplastic polyurethane (TPU) as the base material because it is a biocompatible elastomer with excellent tensility, high abrasion resistance, and good elastic resilience. Various processing parameters, which included the saturation pressure, the foaming temperature, and the membrane thickness, were applied to adjust the TPU membrane's perforated morphology. We proposed a possible formation mechanism of the perforated membrane. The as-prepared TPU membrane had good mechanical properties with a tensile strength of about 5 MPa and an elongation at break above 100%. Such mechanical properties make this novel membrane usable as a self-standing filter device. In addition, its straight-through channel structure can separate particles and meet different separation requirements.

Supercritical fluid-assisted controllable fabrication of open and highly interconnected porous scaffolds for bone tissue engineering

Recently tremendous progress has been evidenced by the advancements in developing innovative three-dimensional (3D) scaffolds using various techniques for addressing the autogenous grafting of bone. In this work, we demonstrated the fabrication of porous polycaprolactone (PCL) scaffolds for osteogenic differentiation based on supercritical fluid-assisted hybrid processes of phase inversion and foaming. This eco-friendly process resulted in the highly porous biomimetic scaffolds with open and interconnected architectures. Initially, a 2³ factorial experiment was designed for investigating the relative significance of various processing parameters and achieving better control over the porosity as well as the compressive mechanical properties of the scaffold. Then, single factor experiment was carried out to understand the effects of various processing parameters on the morphology of scaffolds. On the other hand, we encapsulated a growth factor, i.e., bone morphogenic protein-2 (BMP-2), as a model protein in these porous scaffolds for evaluating their osteogenic differentiation. In vitro investigations of growth factor loaded PCL scaffolds using bone marrow stromal cells (BMSCs) have shown that these growth factor-encumbered scaffolds were capable of differentiating the cells over the control experiments. Furthermore, the osteogenic differentiation was confirmed by measuring the cell proliferation, and alkaline phosphatase (ALP) activity, which were significantly higher demonstrating the active bone growth. Together, these results have suggested that the fabrication of growth factor-loaded porous scaffolds prepared by the eco-friendly hybrid processing efficiently promoted the osteogenic differentiation and may have a significant potential in bone tissue engineering.

Effect of Cellulose Nanofiber (CNF) Surface Treatment on Cellular Structures and Mechanical Properties of Polypropylene/CNF Nanocomposite Foams via Core-Back Foam Injection Molding

Herein, lightweight nanocomposite foams with expansion ratios ranging from 2⁻10-fold were fabricated using an isotactic polypropylene (iPP) matrix and cellulose nanofiber (CNF) as the reinforcing agent via core-back foam injection molding (FIM). Both the native and modified CNFs, including the different degrees of substitution (DS) of 0.2 and 0.4, were melt-prepared and used for producing the polypropylene (PP)/CNF composites. Foaming results revealed that the addition of CNF greatly improved the foamability of PP, reaching 2⁻3 orders of magnitude increases in cell density, in comparison to those of the neat iPP foams. Moreover, tensile test results showed that the incorporation of CNF increased the tensile modulus and yield stress of both solid and 2-fold foamed PP, and a greater reinforcing effect was achieved in composites containing modified CNF. In the compression test, PP/CNF composite foams prepared with a DS of 0.4 exhibited dramatic improvements in mechanical performance for 10-fold foams, in comparison to iPP, with increases in the elastic modulus and collapse stress of PP foams of 486% and 468%, respectively. These results demonstrate that CNF is extraordinarily helpful in enhancing the foamability of PP and reinforcing PP foams, which has importance for the development of lightweight polymer composite foams containing a natural nanofiber.