Solid-state compounding of immiscible PCL-PEO blend powders for molding processes.

Solid-state milling is a promising ecologically friendly method for fabricating polymeric blend and composite powder raw materials for several subsequent manufacturing processes. Biodegradable polymers, blends, and composites are expected to find extensive use by industry due to their environmental friendliness and acceptable mechanical and thermal properties for several applications. Poly-ε-caprolactone (PCL), poly-ethylene-oxide (PEO), and their blends have attracted so much attention to replace commodity polymers in future applications. Therefore, in the current research, bulk compounding of PCL-PEO blends with various compositions using solid-state cryomilling was investigated. Structural, mechanical, thermal, and hydrophilicity properties were examined on samples obtained by compression molding to explore the capabilities of the milling process for various applications. Morphology of the blends was explored by scanning electron microscopy (SEM), which showed a clear phase separation in blends after heating. Dispersed as well as co-continuous morphologies were achieved by varying composition. Differential scanning calorimetry (DSC) and x-ray diffraction (XRD) of the blends indicated insignificant amorphization by milling. Tensile strength, modulus, and percentage elongation at break of the blends demonstrated significant variations due to processing parameters.

Porous poly(ε-caprolactone) scaffolds for load-bearing tissue regeneration: solventless fabrication and characterization.

Three-dimensional interconnected porous poly(ε-caprolactone) scaffolds have been prepared by a novel solventless scaffold fabrication approach combining cryomilling and compression molding/porogen leaching techniques. This study investigated the effects of processing parameters on scaffold morphology and properties for tissue regeneration. Specifically, the effects of molding temperature, cryomilling time, and porogen mix were examined. Fifty percentage of porous scaffolds were fabricated with a range of properties: mean pore size from ∼40 to 125 µm, water uptake from ∼50 to 86%, compressive modulus from ∼45 to 84 MPa, and compressive strength at 10% strain from ∼3 to 4 MPa. Addition of 60 wt % NaCl salt resulted in a ∼50% increase in porosity in multimodal pore-size structures that depended on the method of NaCl addition. Water uptake ranged from ∼61 to 197%, compressive modulus from ∼4 to 8.6 MPa, and compressive strength at 10% strain from ∼0.36 to 0.40 MPa. Results suggest that this approach provides a controllable strategy for the design and fabrication of 3D interconnected porous biodegradable scaffolds for load-bearing tissue regeneration.

Fabrication and characterization of interconnected porous biodegradable poly(ε-caprolactone) load bearing scaffolds.

In this study, poly(ε-caprolactone) (PCL)/poly(ethylene oxide) (PEO) (50:50 wt%) immiscible blend was used as a model system to investigate the feasibility of a novel solventless fabrication approach that combines cryomilling, compression molding and porogen leaching techniques to prepare interconnected porous scaffolds for tissue engineering. PCL was cryomilled with PEO to form blend powders. Compression molding was used to consolidate and anneal the cryomilled powders. Selective dissolution of the PEO with water resulted in interconnected porous scaffolds. Sodium chloride salt (NaCl) was subsequently added to cryomilled powder to increase the porosity of scaffolds. The prepared scaffolds had homogeneous pore structures, a porosity of ~50% which was increased by mixing salt with the blend (~70% for 60% wt% NaCl), and a compressive modulus and strength (ε = 10%) of 60 and 2.8 MPa, respectively. The results of the study confirm that this novel approach offers a viable alternative to fabricate scaffolds.

Solid-state cryomilling for porogen mixing and porous scaffold fabrication - biomed 2011.

Several widely used techniques for the fabrication of three dimensional (3D) scaffolds utilize the particulate leaching method to achieve a porous structure. This method involves the selective leaching of a mineral or an organic compound to generate pores. However, scaffolds prepared by this technique tend to exhibit limited interconnectivity. Therefore, to enhance the interconnectivity of the scaffolds fabricated by particulate leaching, a polymeric porogen can be added during processing. Typically porogens are mixed into a polymer solution, powder, or melt. The mixture is subsequently cast, molded, or extruded, and then leaching the porogens results in porous scaffolds. Still, even though scaffold interconnectivity is improved through the addition of polymer porogens, particulate leaching does not yield scaffolds with uniform properties. This research introduces a new solventless approach, cryomilling, to blend porogens and attain interconnected porous scaffolds with uniform morphologies. To validate the efficacy of the suggested approach a comparison of the effect of various solid-state mixing approaches on scaffold morphology and mechanical properties will be made. In this study, salt particles and poly(ethylene oxide) (PEO) were mixed (manually or through cryomilling) with poly(e-caprolactone) (PCL) for the preparation of porous 3D PCL scaffolds, the mixtures were then compression molded, and subsequently, water was used to leach the porogens. Morphological and compressive properties of the resulting scaffolds will be discussed. This simple, novel, economical, organic solvent-free approach for the fabrication of 3D interconnected porous scaffolds holds promise for tissue engineering applications.