Controlling the hierarchical microstructure of bioceramic scaffolds by 3D printing of emulsion inks

Abstract

Mechanical and biological properties constitute the most fundamental requirements for bone tissue engineering (BTE) scaffolds. Nonetheless, existing fabrication strategies find it difficult to prepare highly porous BTE scaffolds for improved biological properties while also preserving sufficient mechanical properties that are compatible with the natural bone. Inspired by the hierarchical porous materials in Nature, hierarchical porous BTE scaffolds can achieve a combination of superior mechanical efficiency and biological functions. With this in mind, this study reports the fabrication of hierarchical porous hydroxyapatite (hpHA) scaffolds by 3D printing of emulsion inks. The scaffolds exhibit high porosity up to 73.7%, featuring 3D printed macropores of 300 – 400 µm and emulsion templated microporosity of < 20 µm. Via formulation of the emulsion inks, such as varying the oil volume and adding Pluronic® F-127, this process demonstrates effective control of the microporosity and pore morphology of the scaffolds. The scaffolds are mechanically compatible with the natural cancellous bone, with compressive strength in the range of 1.41 – 7.84 MPa and Young's modulus of 57.3 – 304 MPa. Furthermore, the elastic admissible strain (EAS) and specific energy absorption (SEA) of the hpHA scaffolds can be increased up to 4.4% and 1.22 kJ/kg, respectively, indicating greatly enhanced mechanical performances owing to the hierarchical porous structure. Meanwhile, improved cell attachment, spreading and proliferation are observed in these scaffolds with their additional microporosity. Hence, the hpHA scaffolds in this study show great potential in BTE applications, and the reported process of 3D printing of emulsion inks is a promising fabrication strategy for further optimization of highly porous BTE scaffolds.