A novel method to obtain protein release from porous polymer scaffolds: emulsion coating.

To obtain the controlled release of proteins from macro-porous polymeric scaffolds, a novel emulsion-coating method has been developed. In this process, a water-in-oil emulsion, from an aqueous protein solution and a polymer solution, is forced through a prefabricated scaffold by applying a vacuum. After solvent evaporation, a polymer film, containing the protein, is then deposited on the porous scaffold surface. This paper reports the effect of processing parameters on the emulsion coating characteristics, scaffold structure, and protein release and stability. Poly(ether-ester) multiblock copolymers were chosen as the polymer matrix for both scaffolds and coating. Macro-porous scaffolds, with a porosity of 77 vol% and pores of approximately 500 microm were prepared by compression moulding/salt leaching. A micro-porous, homogeneous protein-loaded coating could be obtained on the scaffold surface. Due to the coating, the scaffold porosity was decreased, whereas the pore interconnection was increased. A model protein (lysozyme) could effectively be released in a controlled fashion from the scaffolds. Complete lysozyme release could be achieved within 3 days up to more than 2 months by adjusting the coated emulsion parameters. In addition, the coating process did not reduce the enzymatic activity. This new method appears to be promising for tissue engineering applications.

Bone growth in biomimetic apatite coated porous Polyactive 1000PEGT70PBT30 implants.

We recently, developed a simple one-day one-step incubation method to obtain bone-like apatite coating on flexible and biodegradable Polyactive 1000PEGT70PBT30. The present study reports a preliminary biological evaluation on the coated polymer after implantation in rabbit femurs. The porous cylindrical implants were produced from a block fabricated by injection molding and salt leaching. This technique provided the block necessary mechanical integrity to make small cylinders (diameter 3.5 x 5 mm2) that were suitable for implantation in rabbits. The coating continuously covered the surface of the polymer, preserving the porous architecture of outer contour of the cylinders. Two defects with a diameter of 3.5 or 4 mm were drilled in the proximal and distal part of femur diaphysis. The implants were inserted as press-fit or undersized into the cortex as well as in the marrow cavity. The polymer swelled after implantation due to hydration, leading to a tight contact with the surrounding bone in both defects. The adherence of the coating on the polymer proved to be sufficient to endure a steam sterilization process as well as the 15% swelling of the polymer in vivo. The coated Polyactive 1000PEGT70PBT30 has a good osteoconductive property, as manifested by abundant bone growth into marrow cavity along the implant surface during 4-week implantation. A favorable bioactive effect of the coating with an intimate bone contact and extensive bone bonding with this polymer was qualitatively confirmed. Concerning the bone ingrowth into the porous implant in the defect of 4 mm diameter, only marginal bone formation was observed up to 8 weeks with a maximal penetration depth of about 1 mm. The pore interconnectivity is important not only for producing a coating inside the porous structure but also for bone ingrowth into this biodegradable material. This preliminary study provided promising evidence for a further study using a bigger animal model.

Biomimetic calcium phosphate coatings on Polyactive 1000/70/30.

Precalcification of Polyactive 1000/70/30 with a biomimetic calcium phosphate coating is expected to enhance the bioactivity of this biodegradable polymer for the application as bone filler or scaffold of bone tissue engineering. This study presents a 1-day one-step incubation method to obtain either amorphous or bone-like apatitic calcium phosphate coating on Polyactive 1000/70/30. Either dense plates or three-dimensional porous blocks of the polymer were incubated in a simplified but concentrated simulated body fluid-derived solution at 37 degrees C. By bubbling CO2 gas, a solution was prepared with calcium and phosphate ion concentrations five times of that of regular simulated body fluid. With controlled stirring, the CO2 was released out of the solution and exchanged by air. The pH of the solution increased to induce coating formation. Adjusting stirring rate and CO2/air exchange rate controlled the process kinetics. The reaction kinetics had little influence on the crystallographic structure of the final coating mineral for a given solution composition as shown by Fourier transform infrared spectroscopy and X-ray diffraction. However, the interface structure between the coating and substrate was kinetics-dependent. A fast precipitation condition resulted in a uniform but superficial calcification pattern at the surface of polymer. A slow process by selecting either a slow stirring or a slow CO2/air exchange, on the contrary, induced a localized but deep inside calcification pattern. A tensile test showed no statistically significant difference in the mechanical properties among uncoated and coated polymers. The cracking behavior of coatings from different kinetics, however, exhibited different manners, as can be attributed to different interface structures and interfacial strengths.