Achieving interconnected pore architecture in injectable PolyHIPEs for bone tissue engineering

New Approach for Preparation of Porous Polymers with Reversible Pore Structures for a Highly Safe Smart Supercapacitor

Porous polymers have many industrial applications, but their pore structures (open or closed) are usually fixed during polymerization. In this study, polymers with reversible and controllable pore structures, namely, thermosensitive porous hydrogels with regulated volume phase transition temperature, were prepared using a Pickering high-internal-phase emulsion as the template. Upon heating, the hydrogels transformed not only in their wettability (between hydrophilicity and hydrophobicity with water contact angles of 21.8 and 100.9°) but also their pore structure (between open through-holes and closed holes with pore throat sizes of 15.58 and 0 μm, respectively) in a short time (<10 s). When the hydrogel was used as a separator in smart supercapacitors (SCs), this behavior effectively limited the path of electrolyte migration, reducing the chance of conflagration accidents. Moreover, by utilizing the highly reversible pore structures and wettability of the porous hydrogel, reversible charging and discharging were restored after the system cooled down. This work not only provides great guidance for preparing porous polymers with reversible pore structures but also paves the way for designing smart SCs with enhanced safety.

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

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

Hydroxyapatite nanoparticle-modified porous bone grafts with improved cell attachment

Emulsion-templated foams have displayed promise as injectable bone grafts; however, the use of a surfactant as an emulsifier resulted in relatively small pores and impedes cell attachment. Hydroxyapatite nanoparticles were explored as an alternative stabilizer to address these limitations. To this end, hydroxyapatite nanoparticles were first modified with myristic acid to generate the appropriate balance of hydrophobicity to stabilize a water-in-oil emulsion of neopentyl glycol diacrylate and 1,4-butanedithiol. In situ surface modification of the resulting foam with hydroxyapatite was confirmed with elemental mapping and transmission electron microscopy. Nanoparticle-stabilized foams displayed improved human mesenchymal stem cell viability (91 ± 5%) over surfactant-stabilized foams (23 ± 11%). Although the pore size was appropriate for bone grafting applications (115 ± 71 μm), the foams lacked the interconnected architecture necessary for cell infiltration. We hypothesized that a co-stabilization approach with both surfactant and nanoparticles could be used to achieve interconnected pores while maintaining improved cell attachment and larger pore sizes. A range of hydroxyapatite nanoparticle and surfactant concentrations were investigated to determine the effects on microarchitecture and cell behavior. By balancing these interactions, a co-stabilized foam was identified that possessed large, interconnected pores (108 ± 67 μm) and improved cell viability and attachment. The co-stabilized foam was then evaluated as an injectable bone graft including network formation, microscale integration with bone, push out strength, and compressive properties. Overall, this work demonstrated that in situ surface modification with nHA improved cell attachment while retaining desirable bone grafting features and injectability.

Synthesis and Applications of Elastomeric Polymerized High Internal Phase Emulsions (PolyHIPEs)

Polymer foams (PFs) are among the most industrially produced polymeric materials, and they are found in applications including aerospace, packaging, textiles, and biomaterials. PFs are predominantly prepared using gas-blowing techniques, but PFs can also be prepared from templating techniques such as polymerized high internal phase emulsions (polyHIPEs). PolyHIPEs have many experimental design variables which control the physical, mechanical, and chemical properties of the resulting PFs. Both rigid and elastic polyHIPEs can be prepared, but while elastomeric polyHIPEs are less commonly reported than hard polyHIPEs, elastomeric polyHIPEs are instrumental in the realization of new materials in applications including flexible separation membranes, energy storage in soft robotics, and 3D-printed soft tissue engineering scaffolds. Furthermore, there are few limitations to the types of polymers and polymerization methods that have been used to prepare elastic polyHIPEs due to the wide range of polymerization conditions that are compatible with the polyHIPE method. In this review, an overview of the chemistry used to prepare elastic polyHIPEs from early reports to modern polymerization methods is provided, focusing on the applications that flexible polyHIPEs are used in. The review consists of four sections organized around polymer classes used in the preparation of polyHIPEs: (meth)acrylics and (meth)acrylamides, silicones, polyesters and polyurethanes, and naturally occurring polymers. Within each section, the common properties, current challenges, and an outlook is suggested on where elastomeric polyHIPEs can be expected to continue to make broad, positive impacts on materials and technology for the future.

Polystyrene Macroporous Magnetic Nanocomposites Synthesized through Deep Eutectic Solvent-in-Oil High Internal Phase Emulsions and Fe3O4 Nanoparticles for Oil Sorption

In this work, we report a nonaqueous one-step method to synthesize polystyrene macroporous magnetic nanocomposites through high internal phase emulsions (HIPEs) formulated with the deep eutectic solvent (DES) composed of urea:choline chloride (U:ChCl, in a 2:1 molar ratio) as the internal phase and co-stabilized with mixtures of Span 60 surfactant and non-functionalized magnetite nanoparticles (Fe₃O₄ NPs). The porous structure and the magnetic and lipophilic properties of the nanocomposite materials were easily tailored by varying the amount of Fe₃O₄ NPs (0, 2, 5 and 10 wt %) and the surfactant Span 60 (0, 5, 10, and 20 wt %) used in the precursor emulsion. The resultant nanocomposite polyHIPEs exhibit high sorption capacity toward different oils (hexane, gasoline, and vegetable oil) due to their high porosity, interconnectivity, and hydrophobic surface. It was observed that the oil sorption capacity was improved when the amount of surfactant decreased and Fe₃O₄ NPs increased in HIPE formulation. Therefore, polyHIPE formulated with 5 and 10 wt % Span 60 and Fe₃O₄ NPs, respectively, showed the highest oil sorption capacities of 4.151, 3.556, and 3.266 g g^-1 for gasoline, hexane, and vegetable oil, respectively. In addition, the magnetic monoliths were reused for more than ten sorption/desorption cycles without losing their oil sorption capacity.

Interconnectivity and morphology control of poly-high internal phase emulsions under photo-polymerization

We here demonstrate that the interconnectivity and morphology of photo-polymerized HIPEs can be controlled by changing the type of initiators and stabilizers, and the intensity of light.

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

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

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

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

CAD/CAM scaffolds for bone tissue engineering: investigation of biocompatibility of selective laser melted lightweight titanium

The objective of the current in-vitro study was to evaluate the biocompatibility of a new type of CAD/CAM scaffold for bone tissue engineering by using human cells. Porous lightweight titanium scaffolds and Bio-Oss® scaffolds as well as their eluates were used for incubation with human osteoblasts, fibroblasts and osteosarcoma cells. The cell viability was assessed by using fluorescein diazo-acetate propidium iodide staining. Cell proliferation and metabolism was examined by using MTT-, WST-Test and BrdU-ELISA tests. Scanning electron microscope was used for investigation of the cell adhesion behaviour. The number of devitalised cells in all treatment groups did not significantly deviate from the control group. According to MTT and WST results, the number of metabolically active cells was decreased by the eluates of both test groups with a more pronounced impact of the eluate from Bio-Oss®. The proliferation of the cells was inhibited by the addition of the eluates. Both scaffolds showed a partial surface coverage after 1 week and an extensive to complete coverage after 3 weeks. The CAD/CAM titanium scaffolds showed favourable biocompatibility compared to Bio-Oss® scaffolds in vitro. The opportunity of a defect-specific design and rapid prototyping by selective laser melting are relevant advantages in the field of bone tissue engineering and regenerative medicine.

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

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

Considerations Using Additive Manufacture of Emulsion Inks to Produce Respiratory Protective Filters Against Viral Respiratory Tract Infections Such as the COVID-19 Virus

This review paper explores the potential of combining emulsion-based inks with additive manufacturing (AM) to produce filters for respiratory protective equipment (RPE) in the fight against viral and bacterial infections of the respiratory tract. The value of these filters has been highlighted by the current severe acute respiratory syndrome coronavirus-2 crisis where the importance of protective equipment for health care workers cannot be overstated. Three-dimensional (3D) printing of emulsions is an emerging technology built on a well-established field of emulsion templating to produce porous materials such as polymerized high internal phase emulsions (polyHIPEs). PolyHIPE-based porous polymers have tailorable porosity from the submicron to 100 s of µm. Advances in 3D printing technology enables the control of the bulk shape while a micron porosity is controlled independently by the emulsion-based ink. Herein, we present an overview of the current polyHIPE-based filter applications. Then, we discuss the current use of emulsion templating combined with stereolithography and extrusion-based AM technologies. The benefits and limitation of various AM techniques are discussed, as well as considerations for a scalable manufacture of a polyHIPE-based RPE.

Review of Integrin-Targeting Biomaterials in Tissue Engineering

The ability to direct cell behavior has been central to the success of numerous therapeutics to regenerate tissue or facilitate device integration. Biomaterial scientists are challenged to understand and modulate the interactions of biomaterials with biological systems in order to achieve effective tissue repair. One key area of research investigates the use of extracellular matrix-derived ligands to target specific integrin interactions and induce cellular responses, such as increased cell migration, proliferation, and differentiation of mesenchymal stem cells. These integrin-targeting proteins and peptides have been implemented in a variety of different polymeric scaffolds and devices to enhance tissue regeneration and integration. This review first presents an overview of integrin-mediated cellular processes that have been identified in angiogenesis, wound healing, and bone regeneration. Then, research utilizing biomaterials are highlighted with integrin-targeting motifs as a means to direct these cellular processes to enhance tissue regeneration. In addition to providing improved materials for tissue repair and device integration, these innovative biomaterials provide new tools to probe the complex processes of tissue remodeling in order to enhance the rational design of biomaterial scaffolds and guide tissue regeneration strategies.

Skin-Like Stretchable Fuel Cell Based on Gold-Nanowire-Impregnated Porous Polymer Scaffolds

Skin-like energy devices can be conformally attached to the human body, which are highly desirable to power soft wearable electronics in the future. Here, a skin-like stretchable fuel cell based on ultrathin gold nanowires (AuNWs) and polymerized high internal phase emulsions (polyHIPEs) scaffolds is demonstrated. The polyHIPEs can offer a high porosity of 80% yet with an overall thickness comparable to human skin. Upon impregnation with electronic inks containing ultrathin (2 nm in diameter) and ultrahigh aspect-ratio (>10 000) gold nanowires, skin-like strain-insensitive stretchable electrodes are successfully fabricated. With such designed strain-insensitive electrodes, a stretchable fuel cell is fabricated by using AuNWs@polyHIPEs, platinum (Pt)-modified AuNWs@polyHIPEs, and ethanol as the anode, cathode, and fuel, respectively. The resulting epidermal fuel cell can be patterned and transferred onto skin as "tattoos" yet can offer a high power density of 280 µW cm^-2 and a high durability (>90% performance retention under stretching, compression, and twisting). The results presented here demonstrate that this skin-thin, porous, yet stretchable electrode is essentially multifunctional, simultaneously serving as a current collector, an electrocatalyst, and a fuel host, indicating potential applications to power future soft wearable 2.0 electronics for remote healthcare and soft robotics.

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

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

Lattice Boltzmann simulations capture the multiscale physics of soft flowing crystals

The study of the underlying physics of soft flowing materials depends heavily on numerical simulations, due to the complex structure of the governing equations reflecting the competition of concurrent mechanisms acting at widely disparate scales in space and time. A full-scale computational modelling remains a formidable challenge since it amounts to simultaneously handling six or more spatial decades in space and twice as many in time. Coarse-grained methods often provide a viable strategy to significantly mitigate this issue, through the implementation of mesoscale supramolecular forces designed to capture the essential physics at a fraction of the computational cost of a full-detail description. Here, we review some recent advances in the design of a lattice Boltzmann mesoscale approach for soft flowing materials, inclusive of near-contact interactions (NCIs) between dynamic interfaces, as they occur in high packing-fraction soft flowing crystals. The method proves capable of capturing several aspects of the rheology of soft flowing crystals, namely, (i) a 3/2 power-law dependence of the dispersed phase flow rate on the applied pressure gradient, (ii) the structural transition between an ex-two and ex-one (bamboo) configurations with the associated drop of the flow rate, (iii) the onset of interfacial waves once NCI is sufficiently intense. This article is part of the theme issue 'Fluid dynamics, soft matter and complex systems: recent results and new methods'.

A review of calcium phosphate cements and acrylic bone cements as injectable materials for bone repair and implant fixation

Treatment of bone defects caused by trauma or disease is a major burden on human healthcare systems. Although autologous bone grafts are considered as the gold standard, they are limited in availability and are associated with post-operative complications. Minimally invasive alternatives using injectable bone cements are currently used in certain clinical procedures, such as vertebroplasty and balloon kyphoplasty. Nevertheless, given the high incidence of fractures and pathologies that result in bone voids, there is an unmet need for injectable materials with desired properties for minimally invasive procedures. This paper provides an overview of the most common injectable bone cement materials for clinical use. The emphasis has been placed on calcium phosphate cements and acrylic bone cements, while enabling the readers to compare the opportunities and challenges for these two classes of bone cements. This paper also briefly reviews antibiotic-loaded bone cements used in bone repair and implant fixation, including their efficacy and cost for healthcare systems. A summary of the current challenges and recommendations for future directions has been brought in the concluding section of this paper.

Combined Porogen Leaching and Emulsion Templating to produce Bone Tissue Engineering Scaffolds

Bone has a hierarchy of porosity that is often overlooked when creating tissue engineering scaffolds where pore sizes are typically confined to a single order of magnitude. High internal phase emulsion (HIPE) templating produces polymerized HIPEs (polyHIPEs): highly interconnected porous polymers which have two length scales of porosity covering the 1-100 μm range. However, additional larger scales of porosity cannot be introduced in the standard emulsion formulation. Researchers have previously overcome this by additively manufacturing emulsions; fabricating highly microporous struts into complex macroporous geometries. This is time consuming and expensive; therefore, here we assessed the feasibility of combining porogen leaching with emulsion templating to introduce additional macroporosity. Alginate beads between 275 and 780 μm were incorporated into the emulsion at 0, 50, and 100 wt%. Once polymerized, alginate was dissolved leaving highly porous polyHIPE scaffolds with added macroporosity. The compressive modulus of the scaffolds decreased as alginate porogen content increased. Cellular performance was assessed using MLO-A5 post-osteoblasts. Seeding efficiency was significantly higher and mineralized matrix deposition was more uniformly deposited throughout porogen leached scaffolds compared to plain polyHIPEs. Deep cell infiltration only occurred in porogen leached scaffolds as detected by histology and lightsheet microscopy. This study reveals a quick, low cost and simple method of producing multiscale porosity scaffolds for tissue engineering.

Formulation and polymerization of foamed 1,4-BDDMA-in-water emulsions

Emulsion and foam templating allow the synthesis of tailor-made polymer foams. A complementary templating route is foamed emulsion templating. The concept is based on the generation of a monomer-in-water emulsion which is subsequently foamed. After polymerization of the foamed emulsion, one obtains open-cell polymer foams with porous pore walls. In the paper at hand, we generated foamed emulsions and synthesized polymer foams which are based on the monomer 1,4-butanediol dimethacrylate (1,4-BDDMA). The main challenge was to find the optimal composition of the emulsion by varying the components systematically. We will discuss that the composition of the monomer-in-water emulsion is key for the stability of the foamed emulsion and thus for the structure of the resulting polymer foam. The final composition of the continuous phase was found to be 65 vol% 1,4-BDDMA, 30 vol% water and 5 vol% glycerol. We foamed and polymerized this emulsion to check the foamed emulsion's suitability as a template for solid polymer foams. We generated a foamed emulsion with a mean bubble diameter of 151 μm ± 90 μm and obtained a highly porous poly(1,4-BDDMA) foam with a pore mean diameter of 366 μm ± 91 μm. Furthermore, the polymer foam has a “sub-porosity” within the pore walls.

Emulsion and foam templating allow the synthesis of tailor-made polymer foams.

Methacrylate-based polymer foams with controllable connectivity, pore shape, pore size and polydispersity

Polymer foams are becoming increasingly important in industry, especially biodegradable polymer foams are in demand. Depending on the application, polymer foams need to have characteristic properties, which include connectivity and polydispersity. We show how polymer foams with tailor-made structures can be synthesized from water-in-monomer emulsions which were generated via microfluidics. As monomer we used 1,4-butanediol dimethacrylate (1,4-BDDMA). Firstly, we synthesised monodisperse open- and closed-cell poly(1,4-BDDMA) foams with either spherical or hexagonal pore shapes by varying the locus of initiation. Secondly, we were able to control the pore diameters and obtained polymer foams of both connectivities and pore shapes with pore sizes from ∼70 μm up to ∼120 μm by means of one microfluidic chip. Finally, we synthesized poly(1,4-BDDMA) foams with controllable polydispersity. Here, the mean droplet diameter was the same as that of the monodisperse counterparts in order to be able to compare the properties of the resulting polymer foams.

Oil-in-eutectic mixture HIPEs co-stabilized with surfactant and nanohydroxyapatite: ring-opening polymerization for nanocomposite scaffold synthesis

Mixtures of a nonionic surfactant and non-functionalized nanohydroxyapatite (NHA) enhanced the stability of oil-in-eutectic mixture high internal phase emulsions (HIPEs). Upon ring opening polymerization of the eutectic mixture composed of l-lactide and ε-caprolactone, biodegradable polyHIPEs with specific cavity sizes and selective interfacial functionalization with NHA are produced.

Preparation of Macroporous Polymers from Microcapsule-Stabilized Pickering High Internal Phase Emulsions

The ability to make stable water-in-oil (W/O) Pickering high internal phase emulsions (HIPEs) is demonstrated using microcapsules as a stabilizer. The microcapsules are prepared with glycidyl methacrylate (GMA) and poly(melamine-formaldehyde) (PMF) as core and wall materials, respectively. Using these GMA-loaded PMF-walled microcapsules as a sole stabilizer of water-in-styrene/divinylbenzene HIPE, the polymerization of this HIPE causes a closed-cell porous polymer. While with the addition of a certain amount of the nonionic surfactant Span80 to the microcapsule-stabilized HIPEs, a series of open-cell porous materials are obtained. The morphologies of the porous materials are tunable with changing the microcapsules content and/or surfactant amount in the HIPE templates. When Raft polymerization is introduced to cure these HIPEs, owing to both the self-healing agent GMA within the microcapsules and the residue of the chain-transfer agent from Raft polymerization of HIPEs, the resulting porous polymers are proved to be self-repairable. This work suggests a new type of Pickering HIPE and provides a novel idea for preparing self-healing porous materials.

Porous PolyHIPE microspheres for protein delivery from an injectable bone graft

Delivery of osteoinductive factors such as bone morphogenetic protein 2 (BMP-2) has emerged as a prominent strategy to improve regeneration in bone grafting procedures. However, it remains challenging to identify a carrier that provides the requisite loading efficiency and release kinetics without compromising the mechanical properties of the bone graft. Previously, we reported on porous, polymerized high internal phase emulsion (polyHIPE) microspheres fabricated using controlled fluidics. Uniquely, this solvent-free method provides advantages over current microsphere fabrication strategies including in-line loading of growth factors to improve loading efficiency. In the current study, we utilized this platform to fabricate protein-loaded microspheres and investigated the effect of particle size (∼400 vs ∼800 μm) and pore size (∼15 vs 30 μm) on release profiles. Although there was no significant effect of these variables on the substantial burst release profile of the microspheres, the incorporation of the protein-loaded microspheres within the injectable polyHIPE resulted in a sustained release of protein from the bulk scaffold over a two-week period with minimal burst release. Bioactivity retention of encapsulated BMP-2 was confirmed first using a genetically-modified osteoblast reporter cell line. A functional assay with human mesenchymal stem cells established that the BMP-2 release from microspheres induced osteogenic differentiation. Finally, microsphere incorporation had minimal effect on the cure and compressive properties of an injectable polyHIPE bone graft. Overall, this work demonstrates that these microsphere-polyHIPE composites have strong potential to enhance bone regeneration through controlled release of BMP-2 and other growth factors. STATEMENT OF SIGNIFICANCE: This manuscript describes a method for solvent-free fabrication of porous microspheres from high internal phase emulsions using a controlled fluids setup. The principles of emulsion templating and fluid dynamics provide exceptional control of particle size and pore architecture. In addition to the advantage of solvent-free fabrication, this method provides in-line loading of protein directly into the pores of the microspheres with high loading efficiencies. The incorporation of the protein-loaded microspheres within an injectable polyHIPE scaffold resulted in a sustained release of protein over a two-week period with minimal burst release. Retention of BMP-2 bioactivity and incorporation of microspheres with minimal effect on scaffold compressive properties highlights the potential of these new bone grafts.

Liquid foam templating - A route to tailor-made polymer foams

Solid foams with pore sizes between a few micrometres and a few millimetres are heavily exploited in a wide range of established and emerging applications. While the optimisation of foam applications requires a fine control over their structural properties (pore size distribution, pore opening, foam density, …), the great complexity of most foaming processes still defies a sound scientific understanding and therefore explicit control and prediction of these parameters. We therefore need to improve our understanding of existing processes and also develop new fabrication routes which we understand and which we can exploit to tailor-make new porous materials. One of these new routes is liquid templating in general and liquid foam templating in particular, to which this review article is dedicated. While all solid foams are generated from an initially liquid(-like) state, the particular notion of liquid foam templating implies the specific condition that the liquid foam has time to find its "equilibrium structure" before it is solidified. In other words, the characteristic time scales of the liquid foam's stability and its solidification are well separated, allowing to build on the vast know-how on liquid foams established over the last 20 years. The dispersed phase of the liquid foam determines the final pore size and pore size distribution, while the continuous phase contains the precursors of the desired porous scaffold. We review here the three key challenges which need to be addressed by this approach: (1) the control of the structure of the liquid template, (2) the matching of the time scales between the stability of the liquid template and solidification, and (3) the preservation of the structure of the template throughout the process. Focusing on the field of polymer foams, this review gives an overview of recent research on the properties of liquid foam templates and summarises a key set of studies in the emerging field of liquid foam templating. It finishes with an outlook on future developments. Occasional references to non-polymeric foams are given if the analogy provides specific insight into a physical phenomenon.

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

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

Porous microspheres support mesenchymal progenitor cell ingrowth and stimulate angiogenesis

Porous microspheres have the potential for use as injectable bone fillers to obviate the need for open surgery. Successful bone fillers must be able to support vascularisation since tissue engineering scaffolds often cease functioning soon after implantation due to a failure to vascularise rapidly. Here, we test the angiogenic potential of a tissue engineered bone filler based on a photocurable acrylate-based high internal phase emulsion (HIPE). Highly porous microspheres were fabricated via two processes, which were compared. One was taken forward and investigated for its ability to support human mesenchymal progenitor cells and angiogenesis in a chorioallantoic membrane (CAM) assay. Porous microspheres with either a narrow or broad size distribution were prepared via a T-junction microfluidic device or by a controlled stirred-tank reactor of the HIPE water in oil in water (w/o/w), respectively. Culture of human embryonic stem cell-derived mesenchymal progenitor (hES-MP) cells showed proliferation over 11 days and formation of cell-microsphere aggregates. In-vitro, hES-MP cells were found to migrate into microspheres through their surface pores over time. The presence of osteoblasts, differentiated from the hES-MP cells, was evidenced through the presence of collagen and calcium after 30 days. Microspheres pre-cultured with cells were implanted into CAM for 7 days and compared with control microspheres without pre-cultured cells. The hES-MP seeded microspheres supported greater angiogenesis, as measured by the number of blood vessels and bifurcations, while the empty scaffolds attracted host chick cell ingrowth. This investigation shows that controlled fabrication of porous microspheres has the potential to create an angiogenic, bone filling material for use as a cell delivery vehicle.

Closed-cell, emulsion-templated hydrogels for latent heat storage applications

Hydrogel polyHIPEs with closed-cell structures were prepared from o/w Pickering HIPEs, and applied in latent heat storage.

Fabrication of biomimetic bone grafts with multi-material 3D printing

Extrusion deposition is a versatile method for the 3D printing of biomaterials such as hydrogels, ceramics, and suspensions. Recently, a new class of emulsion inks were developed that can be used to create tunable, hierarchically porous materials with a cure-on-dispense method. Propylene fumarate dimethacrylate (PFDMA) was selected to fabricate bone grafts using this technology due to its established biocompatibility, osteoconductivity, and good compressive properties. Scaffolds fabricated from PFDMA emulsion inks displayed compressive modulus and yield strength of approximately 15 and 1 MPa, respectively. A decrease in infill (from 100% to 70%) resulted in a six-fold increase in permeability; however, there was also a corollary decrease in mechanical properties. In order to generate scaffolds with increased permeability without sacrificing mechanical strength, a biomimetic approach to scaffold design was used to reinforce the highly porous emulsion inks with a dense cortical shell of thermoplastic polyester. Herein, we present an open source method for printing multi-material bone grafts based on PFDMA polyHIPEs with hierarchical porosity and reinforced with a dense shell of poly(ε-caprolactone) (PCL) or poly(lactic acid) (PLA). A multi-modal printing setup was first developed that combined paste extrusion and high temperature thermoplastic extrusion with high positional accuracy in dual deposition. Scaffolds printed with a PCL shell displayed compressive modulus and yield strength of approximately 30 and 3 MPa, respectively. Scaffolds printed with a PLA shell showed compressive modulus and yield strength of approximately 100 and 10 MPa, respectively. By combining this new paste extrusion of emulsion inks with traditional thermoplastic extrusion printing, we have created scaffolds with superior strength that promote cell viability and proliferation of human mesenchymal stem cells. The development of this technique shows great promise for the fabrication of a myriad of other complex tissue engineered scaffolds.

Prevention of Oxygen Inhibition of PolyHIPE Radical Polymerization using a Thiol-based Crosslinker

Polymerized high internal phase emulsions (polyHIPEs) are highly porous constructs currently under investigation as tissue engineered scaffolds. We previously reported on the potential of redox-initiated polyHIPEs as injectable bone grafts that space fill irregular defects with improved integration and rapid cure. Upon subsequent investigation, the radical-initiated cure of these systems rendered them susceptible to oxygen inhibition with an associated increase in uncured macromer in the clinical setting. In the current study, polyHIPEs with increased resistance to oxygen inhibition were fabricated utilizing a tetrafunctional thiol, pentaerythritol tetrakis(3-mercaptoproprionate), and the biodegradable macromer, propylene fumarate dimethacrylate. Increased concentrations of the tetrathiol additive provided improved oxygen resistance as confirmed by polyHIPE gel fraction while retaining the requisite rapid cure rate, compressive properties, and pore architecture for use as an injectable bone graft. Additionally, thiol-methacrylate polyHIPEs exhibited increased degradation under accelerated conditions and supported critical markers of human mesenchymal stem cell activity. In summary, we have improved upon current methods of fabricating injectable polyHIPE grafts to meet translational design goals of improved polymerization kinetics under clinically relevant conditions without sacrificing key scaffold properties.

Diving into the Finestructure of Macroporous Polymer Foams Synthesized via Emulsion Templating: A Phase Diagram Study

During our studies on emulsion-templated monodisperse polymer foams we found significant differences in the finestructure if the locus of initiation is changed. This motivated us to study the phase behavior of the liquid template. Our studies indicate that the template consists of droplets of three different length scales: The water droplets generated via microfluidics (∼70 μm) are surrounded by a continuous phase in which a w/o emulsion (≤100 nm) coexists with a w/o microemulsion (∼5 nm). We speculate that the w/o-emulsion droplets act as seeds for the porous finestructure observed in AIBN-initiated polymer foams. We have experimental evidence that the w/o emulsion inverts to an o/w emulsion with progressing polymerization. This explains the granular texture observed in KPS-initiated polymer foams. The control of the finestructure is important in the preparation of tailor-made polymer foams because it directly impacts the material's density and thus, in turn, its mechanical stability.

Tailored emulsion-templated porous polymer scaffolds for iPSC-derived human neural precursor cell culture

The work here describes the synthesis of tailor-made, porous, polymeric materials with elastic moduli in the range associated with mammalian brain tissue (0.1–24 kPa).

Macroporous materials: microfluidic fabrication, functionalization and applications

This article provides an up-to-date highly comprehensive overview (594 references) on the state of the art of the synthesis and design of macroporous materials using microfluidics and their applications in different fields.

Monodisperse polystyrene foams via polymerization of foamed emulsions: structure and mechanical properties

A study on how to control the pore size of polystyrene foams generated from foamed emulsion templates and their mechanical properties.

Pore Structure of Macroporous Polymers Using Polystyrene/Silica Composite Particles as Pickering Stabilizers

A novel approach for the preparation of interconnected macroporous polymers with a controllable pore structure was reported. The method was based on the polymerization of water-in-oil Pickering high internal phase emulsion (HIPE) stabilized by polystyrene (PS)/silica composite particles. The composite Pickering stabilizers were facilely obtained by mixing positively charged PS microspheres and negatively charged silica nanoparticles, and their amphiphilicity could be delicately tailored by varying the ratio of PS and silica. The droplet size of Pickering HIPEs was characterized using an optical microscope. The pore structure of polymer foams was observed using a scanning electron microscope. The interconnectivity of macroporous polymers was evaluated upon their gas permeability, which was greatly improved after etching PS microspheres included in the Pickering stabilizers with tetrahydrofuran. As a result, fine tailoring of the pore structure of polymer foams could be realized by simply tuning the ratio of PS to silica particles in the composite stabilizer.

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

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

Osteoinductive PolyHIPE Foams as Injectable Bone Grafts

We have recently fabricated biodegradable polyHIPEs as injectable bone grafts and characterized the mechanical properties, pore architecture, and cure rates. In this study, calcium phosphate nanoparticles and demineralized bone matrix (DBM) particles were incorporated into injectable polyHIPE foams to promote osteoblastic differentiation of mesenchymal stem cells (MSCs). Upon incorporation of each type of particle, stable monoliths were formed with compressive properties comparable to control polyHIPEs. Pore size quantification indicated a negligible effect of all particles on emulsion stability and resulting pore architecture. Alizarin red calcium staining illustrated the incorporation of calcium phosphate particles at the pore surface, while picrosirius red collagen staining illustrated collagen-rich DBM particles within the monoliths. Osteoinductive particles had a negligible effect on the compressive modulus (∼30 MPa), which remained comparable to human cancellous bone values. All polyHIPE compositions promoted human MSC viability (∼90%) through 2 weeks. Furthermore, gene expression analysis indicated the ability of all polyHIPE compositions to promote osteogenic differentiation through the upregulation of bone-specific markers compared to a time zero control. These findings illustrate the potential for these osteoinductive polyHIPEs to promote osteogenesis and validate future in vivo evaluation. Overall, this work demonstrates the ability to incorporate a range of bioactive components into propylene fumarate dimethacrylate-based injectable polyHIPEs to increase cellular interactions and direct specific behavior without compromising scaffold architecture and resulting properties for various tissue engineering applications.

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

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