Robotic deposition of model hydroxyapatite scaffolds with multiple architectures and multiscale porosity for bone tissue engineering.

Model hydroxyapatite (HA) scaffolds with porosities spanning multiple length scales were fabricated by robocasting, a solid freeform fabrication technique based on the robotic deposition of colloidal pastes. Scaffolds of various architectures including periodic, radial, and superlattice structures were constructed. Macropores (100-600 microm) were designed by controlling the arrangement and spacing between rods of HA. Micropores (1-30 microm) and submicron pores (less than 1 microm) were produced within the rods by including polymer microsphere porogens in the HA pastes and by controlling the sintering of the scaffolds. These model scaffolds may be used to systematically study the effects of scaffold porosity on bone ingrowth processes both in vitro and in vivo.

Effects of degradation and porosity on the load bearing properties of model hydroxyapatite bone scaffolds.

Degradation of three types of model hydroxyapatite (HA) scaffolds was studied after in vitro degradation in a sodium acetate buffer (pH 4). Degradation was evaluated using compression testing, scanning electron microscopy (SEM), inductively coupled plasma (ICP) analysis, and weight measurements. Scaffolds were fabricated with a solid freeform fabrication (SFF) technique based on the robotic deposition of colloidal pastes. Scaffolds had a macrostructure resembling a lattice of rods. Scaffolds contained either macropores (270 or 680 microm in the x-y direction and 280 microm in the z-direction) and micropores (1-30-microm pores and pores <1 microm) or only macropores pores (270 microm in the x-y direction and 280 microm in the z-direction). A computer-aided design (CAD) program controlled the size and distribution of macropores; micropores were created by polymethylmethacrylate (PMMA) microsphere porogens (1-30-microm pore diameter) and controlled sintering (pores <1 microm). Percent weight loss of the scaffolds and calcium and phosphorus ion concentrations in solution increased as the degradation period increased for all scaffold types. After degradation, compressive strength and compressive modulus decreased significantly for those scaffolds with microporosity. For scaffolds without microporosity, the changes in strength and modulus after degradation were not statistically significant. The compressive strength of scaffolds without microporosity was significantly greater than the scaffolds with microporosity.

Bone response to 3D periodic hydroxyapatite scaffolds with and without tailored microporosity to deliver bone morphogenetic protein 2.

Three types of model hydroxyapatite (HA) scaffolds were implanted in the metacarpal and metatarsal bones of goats. Scaffolds, consisting of a latticed pattern of rods, were fabricated with a solid freeform fabrication (SFF) technique. All scaffolds contained macropores; some were also fabricated with micropores (5.2 +/- 2.0 microm). Recombinant human bone morphogenetic protein-2 (rhBMP-2) was added to some microporous scaffolds. rhBMP-2 caused increased percent filled with bone tissue compared to microporous scaffolds without rhBMP-2. Lamellar bone in the scaffolds was aligned perpendicular to the long axis of the bone near the junctions of the rods that make up the scaffold but was more random away from the junctions of rods. Microporous scaffolds stained beneath areas of contact with new bone. This staining might indicate either extracellular matrix (ECM) in the rods, byproducts of ECM production, or reaction of cellular products with the scaffold.