Mechanical Study of Polycaprolactone-hydroxyapatite Porous Scaffolds Created by Porogen-based Solid Freeform Fabrication Method

Extrusion-based 3D printing of osteoinductive scaffolds with a spongiosa-inspired structure

Critical-sized bone defects resulting from trauma, inflammation, and tumor resections are individual in their size and shape. Implants for the treatment of such defects have to consider biomechanical and biomedical factors, as well as the individual conditions within the implantation site. In this context, 3D printing technologies offer new possibilities to design and produce patient-specific implants reflecting the outer shape and internal structure of the replaced bone tissue. The selection or modification of materials used in 3D printing enables the adaption of the implant, by enhancing the osteoinductive or biomechanical properties. In this study, scaffolds with bone spongiosa-inspired structure for extrusion-based 3D printing were generated. The computer aided design process resulted in an up scaled and simplified version of the bone spongiosa. To enhance the osteoinductive properties of the 3D printed construct, polycaprolactone (PCL) was combined with 20% (wt) calcium phosphate nano powder (CaP). The implants were designed in form of a ring structure and revealed an irregular and interconnected porous structure with a calculated porosity of 35.2% and a compression strength within the range of the natural cancellous bone. The implants were assessed in terms of biocompatibility and osteoinductivity using the osteosarcoma cell line MG63 and patient-derived mesenchymal stem cells in selected experiments. Cell growth and differentiation over 14 days were monitored using confocal laser scanning microscopy, scanning electron microscopy, deoxyribonucleic acid (DNA) quantification, gene expression analysis, and quantitative assessment of calcification. MG63 cells and human mesenchymal stem cells (hMSC) adhered to the printed implants and revealed a typical elongated morphology as indicated by microscopy. Using DNA quantification, no differences for PCL or PCL-CaP in the initial adhesion of MG63 cells were observed, while the PCL-based scaffolds favored cell proliferation in the early phases of culture up to 7 days. In contrast, on PCL-CaP, cell proliferation for MG63 cells was not evident, while data from PCR and the levels of calcification, or alkaline phosphatase activity, indicated osteogenic differentiation within the PCL-CaP constructs over time. For hMSC, the highest levels in the total calcium content were observed for the PCL-CaP constructs, thus underlining the osteoinductive properties.

Injection Molding Process Simulation of Polycaprolactone Sticks for Further 3D Printing of Medical Implants

The aim of the present study was a simulation of the injection molding process of polycaprolactone filament sticks for further 3D printing of osteochondral implants. Polycaprolactone data are not available in the data banks of popular injection molding simulation programs. Therefore, thermal and rheological data from the literature were imported to the material database of Solidworks Plastics software to simulate the injection molding process of filament sticks. The influence of several injection molding parameters including melt temperature, injection time, and injection pressure on the geometry of filament stick (final part) was investigated. Based on the results of the performed simulation and analyses, it was possible to improve the injection process parameters. The accuracy of simulation predictions, based on the literature data, demonstrates the potential of using simulation as a tool to develop polycaprolactone parts for future implants and to optimize the injection molding process.

Investigating Potential Effects of Ultra-Short Laser-Textured Porous Poly-ε-Caprolactone Scaffolds on Bacterial Adhesion and Bone Cell Metabolism

Developing antimicrobial surfaces that combat implant-associated infections while promoting host cell response is a key strategy for improving current therapies for orthopaedic injuries. In this paper, we present the application of ultra-short laser irradiation for patterning the surface of a 3D biodegradable synthetic polymer in order to affect the adhesion and proliferation of bone cells and reject bacterial cells. The surfaces of 3D-printed polycaprolactone (PCL) scaffolds were processed with a femtosecond laser (λ = 800 nm; τ = 130 fs) for the production of patterns resembling microchannels or microprotrusions. MG63 osteoblastic cells, as well as S. aureus and E. coli, were cultured on fs-laser-treated samples. Their attachment, proliferation, and metabolic activity were monitored via colorimetric assays and scanning electron microscopy. The microchannels improved the wettability, stimulating the attachment, spreading, and proliferation of osteoblastic cells. The same topography induced cell-pattern orientation and promoted the expression of alkaline phosphatase in cells growing in an osteogenic medium. The microchannels exerted an inhibitory effect on S. aureus as after 48 h cells appeared shrunk and disrupted. In comparison, E. coli formed an abundant biofilm over both the laser-treated and control samples; however, the film was dense and adhesive on the control PCL but unattached over the microchannels.

Natural Fiber-Reinforced Polycaprolactone Green and Hybrid Biocomposites for Various Advanced Applications

Recent developments within the topic of biomaterials has taken hold of researchers due to the mounting concern of current environmental pollution as well as scarcity resources. Amongst all compatible biomaterials, polycaprolactone (PCL) is deemed to be a great potential biomaterial, especially to the tissue engineering sector, due to its advantages, including its biocompatibility and low bioactivity exhibition. The commercialization of PCL is deemed as infant technology despite of all its advantages. This contributed to the disadvantages of PCL, including expensive, toxic, and complex. Therefore, the shift towards the utilization of PCL as an alternative biomaterial in the development of biocomposites has been exponentially increased in recent years. PCL-based biocomposites are unique and versatile technology equipped with several importance features. In addition, the understanding on the properties of PCL and its blend is vital as it is influenced by the application of biocomposites. The superior characteristics of PCL-based green and hybrid biocomposites has expanded their applications, such as in the biomedical field, as well as in tissue engineering and medical implants. Thus, this review is aimed to critically discuss the characteristics of PCL-based biocomposites, which cover each mechanical and thermal properties and their importance towards several applications. The emergence of nanomaterials as reinforcement agent in PCL-based biocomposites was also a tackled issue within this review. On the whole, recent developments of PCL as a potential biomaterial in recent applications is reviewed.

Experimental and Numerical Simulations of 3D-Printed Polycaprolactone Scaffolds for Bone Tissue Engineering Applications

Ideal bone scaffolds for tissue engineering should be highly porous allowing cell attachment, spreading, and differentiation and presenting appropriate biomechanical properties. These antagonistic characteristics usually require extensive experimental work to achieve optimised balanced properties. This paper presents a simulation approach to determine the mechanical behaviour of bone scaffolds allowing the compressive modulus and the deformation mechanisms to be predicted. Polycaprolactone scaffolds with regular square pores and different porosities were considered. Scaffolds were also printed using an extrusion-based additive manufacturing and assessed under compressive loads. Similar designs were used for both simulation and fabrication steps. A good correlation between numerical and experimental results was obtained, highlighting the suitability of the simulation tool for the mechanical design of 3D-printed bone scaffolds.

Design and fabrication of polycaprolactone/gelatin composite scaffolds for diaphragmatic muscle reconstruction

Diaphragmatic wall defects caused by congenital disorders or disease remain a major challenge for physicians worldwide. Polymeric patches have been extensively explored within research laboratories and the clinic for soft tissue and diaphragm reconstruction. However, patch usage may be associated with allergic reaction, infection, granulation, and recurrence of the hernia. In this study, we designed and fabricated a porous scaffold using a combination of 3D printing and freeze-drying techniques. A 3D printed polycaprolactone (PCL) mesh was used to reinforcegelatin scaffolds, representing an advantage over previously reported examples since it provides mechanical strength and flexibility. In vitro studies showed that adherent cells were anchorage-dependent and grew as a monolayer attached to the scaffolds. Microscopic observations indicated better cell attachments for the scaffolds with higher gelatin content as compared with the PCL control samples. Tensile testing demonstrated the mechanical strength of samples was significantly greater than adult diaphragm tissue. The biocompatibility of the specimens was investigated in vivo using a subcutaneous implantation method in Bagg albino adult mice for 20 days, with the results indicating superior cellular behavior and attachment on scaffolds containing gelatin in comparison to pure PCL scaffolds, suggesting that the porous PCL/gelatin scaffolds have potential as biodegradable and flexible constructs for diaphragm reconstruction.

Poly(ε-Caprolactone)/Brewers’ Spent Grain Composites—The Impact of Filler Treatment on the Mechanical Performance

Waste lignocellulose materials, such as brewers’ spent grain, can be considered very promising sources of fillers for the manufacturing of natural fiber composites. Nevertheless, due to the chemical structure differences between polymer matrices and brewers’ spent grain, filler treatment should be included. The presented work aimed to investigate the impact of fillers’ reactive extrusion on the chemical structure and the poly(ε-caprolactone)/brewers’ spent grain composites’ mechanical performance. The chemical structure was analyzed by Fourier-transform infrared spectroscopy, while the mechanical performance of composites was assessed by static tensile tests and dynamic mechanical analysis. Depending on the filler pretreatment, composites with different mechanical properties were obtained. Nevertheless, the increase in pretreatment temperature resulted in the increased interface surface area of filler, which enhanced composites’ toughness. As a result, composites were able to withstand a higher amount of stress before failure. The mechanical tests also indicated a drop in the adhesion factor, pointing to enhanced interfacial interactions for higher pretreatment temperatures. The presented work showed that reactive extrusion could be considered an auspicious method for lignocellulose filler modification, which could be tailored to obtain composites with desired properties.

Development of polymeric functionally graded scaffolds: a brief review

Over recent years, there has been a growing interest in multilayer scaffolds fabrication approaches. In fact, functionally graded scaffolds (FGSs) provide biological and mechanical functions potentially similar to those of native tissues. Based on the final application of the scaffold, there are different properties (physical, mechanical, biochemical, etc.) which need to gradually change in space. Therefore, a number of different technologies have been investigated, and often combined, to customize each region of the scaffolds as much as possible, aiming at achieving the best regenerative performance.In general, FGSs can be categorized as bilayered or multilayered, depending on the number of layers in the whole structure. In other cases, scaffolds are characterized by a continuous gradient of 1 or more specific properties that cannot be related to the presence of clearly distinguished layers. Since each traditional approach presents peculiar advantages and disadvantages, FGSs are good candidates to overcome the limitations of current treatment options. In contrast to the reviews reported in the literature, which usually focus on the application of FGS, this brief review provides an overview of the most common strategies adopted to prepare FGS.