Simple method to generate and fabricate stochastic porous scaffolds

Forged to heal: The role of metallic cellular solids in bone tissue engineering

Metallic cellular solids, made of biocompatible alloys like titanium, stainless steel, or cobalt-chromium, have gained attention for their mechanical strength, reliability, and biocompatibility. These three-dimensional structures provide support and aid tissue regeneration in orthopedic implants, cardiovascular stents, and other tissue engineering cellular solids. The design and material chemistry of metallic cellular solids play crucial roles in their performance: factors such as porosity, pore size, and surface roughness influence nutrient transport, cell attachment, and mechanical stability, while their microstructure imparts strength, durability and flexibility. Various techniques, including additive manufacturing and conventional fabrication methods, are utilized for producing metallic biomedical cellular solids, each offering distinct advantages and drawbacks that must be considered for optimal design and manufacturing. The combination of mechanical properties and biocompatibility makes metallic cellular solids superior to their ceramic and polymeric counterparts in most load bearing applications, in particular under cyclic fatigue conditions, and more in general in application that require long term reliability. Although challenges remain, such as reducing the production times and the associated costs or increasing the array of available materials, metallic cellular solids showed excellent long-term reliability, with high survival rates even in long term follow-ups.

Additively Manufactured Scaffolds with Optimized Thickness Based on Triply Periodic Minimal Surface

Triply periodic minimal surfaces (TPMS) became an effective method to design porous scaffolds in recent years due to their superior mechanical and other engineering properties. Since the advent of additive manufacturing (AM), different TPMS-based scaffolds are designed and fabricated for a wide range of applications. In this study, Schwarz Primitive triply periodic minimal surface (P-TPMS) is adopted to design a novel porous scaffold according to the distribution of the scaffold stress under a fixed load with optimized thickness to tune both the mechanical and biological properties. The designed scaffolds are then additively manufactured through selective laser melting (SLM). The micro-features of the scaffolds are studied through scanning electron microscopy (SEM) and micro-computed tomography (CT) images, and the results confirm that morphological features of printed samples are identical to the designed ones. Afterwards, the quasi-static uniaxial compression tests are carried out to observe the stress-strain curves and the deformation behavior. The results indicate that the mechanical properties of the porous scaffolds with optimized thickness were significantly improved. Since the mass transport capability is important for the transport of nutrients within the bone scaffolds, computational fluid dynamics (CFD) are used to calculate the permeability under laminar flow conditions. The results reveal that the scaffolds with optimized structures possess lower permeability due to the rougher inner surface. In summary, the proposed method is effective to tailor both the mechanical properties and permeability, and thus offers a means for the selection and design of porous scaffolds in biomedical fields.

The design and evaluation of bionic porous bone scaffolds in fluid flow characteristics and mechanical properties

BACKGROUND AND OBJECTIVE

At present, there is a lack of efficient modeling methods for bionic artificial bone scaffolds, and the tissue fluid/nutrient mass transport characteristics of bone scaffolds has not been evaluated sufficiently. This study aims to explore an effective and efficient modeling method for biomimetic porous bone scaffolds for biological three-dimensional printing based on the imitation of the histomorphological characteristics of human vertebral cancellous bone. The fluid mass transport and mechanical characteristics of the porous scaffolds were evaluated and compared with those of a human cancellous bone,and the relationship between the geometric parameters (e.g., the size, number, shape of pores and porosity) and the performence of biomimetic porous bone scaffolds are revealed.

METHODS

The bionic modeling design method proposed in this study considers the biological characteristics of vertebral cancellous tissue and performs imitation and design of vertebrae-like two-dimensional slices images.It then reconstructs the slices layer-by-layer to form porous scaffolds with a three-dimensional reconstruction method, similar to computed tomography image reconstruction. By controlling the design parameters, this method can easily realize the formation of plate-like (femoral cancellous bone-like) or rod-like (vertebral cancellous bone-like) porous scaffolds. The flow characterization of porous structures was performed using the computational fluid simulation method.

RESULTS

The flow characterization results showed that the permeability of the porous scaffolds and human bone was 10^-8∼10^-9m²,and when the porosity of the porous scaffolds was higher than 70%, the permeability was higher than that of human vertebrae with a porosity of 82%. The maximum shear stress of the designed porous scaffolds and human vertebra were less than 0.8Mpa, which was conducive to cell adhesion, cell migration, and cell differentiation. The results of 3D printing and mechanical testing showed good printability and reflected the relationship between the mechanical properties and design parameters.

CONCLUSIONS

The design method proposed in this study has many controllable parameters, which can be adjusted to generate diversified functional porous structures to meet specific needs, increase the potential of bone scaffold design, and leave room for meeting the new requirements for bone scaffold characteristics in the future.

Additive manufacturing of functionally graded porous titanium scaffolds for dental applications

Graded porous titanium scaffolds are gaining increasing attention as dental implants due to their ability to mimic the mechanical and biological properties of human bone. In this study, we have developed titanium scaffolds with graded primitive structures with porosities of 50.7 %, 61.0 %, 70.5 %, and 80.3 % (denoted as P50, P60, P70, and P80, respectively) for dental applications. The simulation results in the oral environment showed that the maximum von Mises strains and stress of cortical bone tissue around P50, P60, and P70 were lower than 3000 με and 60 MPa, respectively, which was beneficial for bone regeneration. The elastic modulus and yield strength of P50, P60, and P70 ranged within 5.2-13.8 GPa and 88.6-217.8 MPa, respectively. Among these, P60 exhibited the most favorable mechanical properties with a compression yield strength of 163.2 MPa and an elastic modulus of 9.7 GPa, which are desirable mechanical properties for dental material applications. The tested permeabilities of the fabricated specimens were in the range 0.66-6.88 × 10^-9 m², which is within the range of human bone (0.01-12.10 × 10^-9 m²). In vitro biocompatibility assay results showed that P60 and P70 had better potential for cell viability and osteogenesis than P50. It can be concluded that P60, which has a compatible elastic modulus, high yield strength, high permeability, good cytocompatibility, and osteogenesis properties, is a promising candidate for bone-tissue engineering applications in dentistry.

Programmed Plastic Deformation in Mathematically-Designed Architected Cellular Materials

The ability to control the exhibited plastic deformation behavior of cellular materials under certain loading conditions can be harnessed to design more reliable and structurally efficient damage-tolerant materials for crashworthiness and protective equipment applications. In this work, a mathematically-based design approach is proposed to program the deformation behavior of cellular materials with minimal surface-based topologies and ductile constituent material by employing the concept of functional grading to control the local relative density of unit cells. To demonstrate the applicability of this design tactic, two examples are presented. Rhombic, and double arrow deformation profiles were programmed as the desired deformation patterns. Grayscale images were used to map the relative density distribution of the cellular material. 316L stainless steel metallic samples were fabricated using the powder bed fusion additive manufacturing technique. Results of compressive tests showed that the designed materials followed the desired programmed deformation behavior. Results of mechanical testing also showed that samples with programmed deformation exhibited higher plateau stress and toughness values as compared to their uniform counterparts while no effect on Young’s modulus was observed. Plateau stress values increased by 8.6% and 13.4% and toughness values increased by 5.6% and 11.2% for the graded-rhombic and graded-arrow patterns, respectively. Results of numerical simulations predicted the exact deformation behavior that was programmed in the samples and that were obtained experimentally.

Functionally Graded Scaffolds with Programmable Pore Size Distribution Based on Triply Periodic Minimal Surface Fabricated by Selective Laser Melting

Functional graded materials are gaining increasing attention in tissue engineering (TE) due to their superior mechanical properties and high biocompatibility. Triply periodic minimal surface (TPMS) has the capability to produce smooth surfaces and interconnectivity, which are very essential for bone scaffolds. To further enhance the versatility of TPMS, a parametric design method for functionally graded scaffold (FGS) with programmable pore size distribution is proposed in this study. Combining the relative density and unit cell size, the effect of design parameters on the pore size was also considered to effectively govern the distribution of pores in generating FGS. We made use of Gyroid to generate different types of FGS, which were then fabricated using selective laser melting (SLM), followed by investigation and comparison of their structural characteristics and mechanical properties. Their morphological features could be effectively controlled, indicating that TPMS was an effective way to achieve functional gradients which had bone-mimicking architectures. In terms of mechanical performance, the proposed FGS could achieve similar mechanical response under compression tests compared to the reference FGS with the same range of density gradient. The proposed method with control over pore size allows for effectively generating porous scaffolds with tailored properties which are potentially adopted in various fields.

Design and Characterization of Sheet-Based Gyroid Porous Structures with Bioinspired Functional Gradients

A new type of sheet porous structures with functionally gradients based on triply periodic minimal surfaces (TPMS) is proposed for designing bone scaffolds. The graded structures were generated by constructing branched features with different number of sheets. The design of the structure was formulated mathematically and five types of porous structure with different structural features were used for investigation. The relative density (RD) and surface area to volume (SA/V) ratio of the samples were analyzed using a slice-based approach to confirm their relationships with design parameters. All samples were additively manufactured using selective laser melting (SLM), and their physical morphologies were observed and compared with the designed models. Compression tests were adopted to study the mechanical properties of the proposed structure from the obtained stress-strain curves. The results reveal that the proposed branched-sheet structures could enhance and diversify the physical and mechanical properties, indicating that it is a potential method to tune the biomechanical properties of porous scaffolds for bone tissue engineering (TE).

Porous Tantalum and Titanium in Orthopedics: A Review

Porous metal is metal with special porous structures, which can offer high biocompatibility and low Young's modulus to satisfy the need for orthopedic applications. Titanium and tantalum are the most widely used porous metals in orthopedics due to their excellent biomechanical properties and biocompatibility. Porous titanium and tantalum have been studied and applied for a long history until now. Here in this review, various manufacturing methods of titanium and tantalum porous metals are introduced. Application of these porous metals in different parts of the body are summarized, and strengths and weaknesses of these porous metal implants in clinical practice are discussed frankly for future improvement from the viewpoint of orthopedic surgeons. Then according to the requirements from clinics, progress in research for clinical use is illustrated in four aspects. Various creative designs of microporous and functionally gradient structure, surface modification, and functional compound systems of porous metal are exhibited as reference for future research. Finally, the directions of orthopedic porous metal development were proposed from the clinical view based on the rapid progress of additive manufacturing. Controllable design of both macroscopic anatomical bionic shape and microscopic functional bionic gradient porous metal, which could meet the rigorous mechanical demand of bone reconstruction, should be developed as the focus. The modification of a porous metal surface and construction of a functional porous metal compound system, empowering stronger cell proliferation and antimicrobial and antineoplastic property to the porous metal implant, also should be taken into consideration.

Personalized Design of Functional Gradient Bone Tissue Engineering Scaffold

The porous structure of the natural bone not only has the characteristics of lightweight and high strength, but also is conducive to the growth of cells and tissues due to interconnected pores. In this paper, a novel gradient-controlled parametric modeling technology is presented to design bone tissue engineering (BTE) scaffold. First of all, the method functionalizes the pore distribution in the bone tissue, and reconstructs the pore distribution of the bone tissue in combination with the pathological analysis of the bone defect area of the individual patient. Then, based on the reconstructed pore distribution, the Voronoi segmentation algorithm and the contour interface optimization method are used to reconstruct the whole model of the bone tissue. Finally, the mechanical properties of the scaffold are studied by the finite element analysis (FEA) of different density gradient scaffolds. The results show that the method is highly feasible. BTE scaffold can be designed by irregular design methods and adjustment of pore distribution parameters, which is similar with natural bone in structural characteristics and biomechanical properties.

Additive manufacturing of bone scaffolds

Additive manufacturing (AM) can obtain not only customized external shape but also porous internal structure for scaffolds, both of which are of great importance for repairing large segmental bone defects. The scaffold fabrication process generally involves scaffold design, AM, and post-treatments. Thus, this article firstly reviews the state-of-the-art of scaffold design, including computer-aided design, reverse modeling, topology optimization, and mathematical modeling. In addition, the current characteristics of several typical AM techniques, including selective laser sintering, fused deposition modeling (FDM), and electron beam melting (EBM), especially their advantages and limitations are presented. In particular, selective laser sintering is able to obtain scaffolds with nanoscale grains, due to its high heating rate and a short holding time. However, this character usually results in insufficient densification. FDM can fabricate scaffolds with a relative high accuracy of pore structure but with a relative low mechanical strength. EBM with a high beam-material coupling efficiency can process high melting point metals, but it exhibits a low-resolution and poor surface quality. Furthermore, the common post-treatments, with main focus on heat and surface treatments, which are applied to improve the comprehensive performance are also discussed. Finally, this review also discusses the future directions for AM scaffolds for bone tissue engineering.

Design and Compressive Behavior of Controllable Irregular Porous Scaffolds: Based on Voronoi-Tessellation and for Additive Manufacturing

Adjustment of the mechanical properties (apparent elastic modulus and compressive strength) in porous scaffolds is important for artificial implants and bone tissue engineering. In this study, a top-down design method based on Voronoi-Tessellation was proposed. This method was successful in obtaining the porous structures with specified and functionally graded porosity. The porous specimens were prepared by selective laser melting technology. Quasi-static compressive tests were conducted as well. The experiment results revealed that the mechanical properties were affected by both porosity and irregularity. The irregularity coefficient proposed in this study can achieve good accommodation and balance of "irregularity" and "controllability". The method proposed in this study provides an efficient approach for the bionic design and topological optimization of scaffolds.

3D Printed Structures Filled with Carbon Fibers and Functionalized with Mesenchymal Stem Cell Conditioned Media as In Vitro Cell Niches for Promoting Chondrogenesis

In this study, we present a novel approach towards the straightforward, rapid, and low-cost development of biomimetic composite scaffolds for tissue engineering strategies. The system is based on the additive manufacture of a computer-designed lattice structure or framework, into which carbon fibers are subsequently knitted or incorporated. The 3D-printed lattice structure acts as support and the knitted carbon fibers perform as driving elements for promoting cell colonization of the three-dimensional construct. A human mesenchymal stem cell (h-MSC) conditioned medium (CM) is also used for improving the scaffold's response and promoting cell adhesion, proliferation, and viability. Cell culture results-in which scaffolds become buried in collagen type II-provide relevant information regarding the viability of the composite scaffolds used and the prospective applications of the proposed approach. In fact, the advanced composite scaffold developed, together with the conditioned medium functionalization, constitutes a biomimetic stem cell niche with clear potential, not just for tendon and ligament repair, but also for cartilage and endochondral bone formation and regeneration strategies.

Composite scaffolds for osteochondral repair obtained by combination of additive manufacturing, leaching processes and hMSC-CM functionalization

Articular repair is a relevant and challenging area for the emerging fields of tissue engineering and biofabrication. The need of significant gradients of properties, for the promotion of osteochondral repair, has led to the development of several families of composite biomaterials and scaffolds, using different effective approaches, although a perfect solution has not yet been found. In this study we present the design, modeling, rapid manufacturing and in vitro testing of a composite scaffold aimed at osteochondral repair. The presented composite scaffold stands out for having a functional gradient of density and stiffness in the bony phase, obtained in titanium by means of computer-aided design combined with additive manufacture using selective laser sintering. The chondral phase is obtained by sugar leaching, using a PDMS matrix and sugar as porogen, and is joined to the bony phase during the polymerization of PDMS, therefore avoiding the use of supporting adhesives or additional intermediate layers. The mechanical performance of the construct is biomimetic and the stiffness values of the bony and chondral phases can be tuned to the desired applications, by means of controlled modifications of different parameters. A human mesenchymal stem cell (h-MSC) conditioned medium (CM) is used for improving scaffold response. Cell culture results provide relevant information regarding the viability of the composite scaffolds used.