Formation of poly(epsilon-caprolactone) scaffolds loaded with small molecules by integrated processes

Cell stimulation by bioactive molecules has become an important tool in tissue engineering. The homogeneous incorporation of such molecules within the bulk of a polymer-based scaffold compared to surface coating is considered advantageous for most applications and minimizes a burst effect. An efficient way of bulk loading is the incorporation of these molecules during the scaffold formation process. In this paper, two different integrated processes for the preparation of scaffolds from poly(epsilon-caprolactone) (PCL) loaded with a small molecule are investigated. Both formation and loading of the scaffold is carried out in a single-step process. Sudan Red G was selected as a model compound for lipophilic small molecules. A freeze drying and pressure quench (PQ) formation process was selected, and the influence of the small molecule on the formation processes and on the morphology of the obtained scaffold was evaluated and compared. It could be shown for both processes that the formation of loaded scaffolds is possible, and that the small molecule has a very high impact on the foam morphology. In case of the freeze-drying (FD) method, only a load of 1 wt% Sudan Red G was incorporated within the bulk and showed no influence on the foam morphology. In the case of PQ foaming, an incorporation of 43 wt% Sudan Red G was achieved (although tiny crystal needles of the small molecule were found on the surface) and a strong effect on the foam morphology was found. This paper presents an efficient method of incorporating small molecules by integrated processes.