A functionally gradient variational porosity architecture for hollowed scaffolds fabrication

Area of Science:

• Biomaterials Science
• Tissue Engineering
• Additive Manufacturing

Background:

• Fabricating complex, porous scaffolds for tissue engineering presents challenges in controlling architecture and porosity.
• Existing methods often result in design errors and limitations in achieving functionally graded materials.

Purpose of the Study:

• To present a novel continuous tool-path planning methodology for hollowed scaffold fabrication.
• To achieve controllable, variable pore sizes and porosity in tissue scaffolds using a gradient porous architecture.
• To ensure continuous and optimized material deposition for 3D biomaterial printing.

Main Methods:

• Proposed a functionally gradient porous architecture with a continuous material deposition scheme.
• Utilized geometrically oriented consecutive layers with partitioned sub-regions to control pore size and porosity.
• Generated continuous, interconnected tool-paths, including zigzag and concentric spiral patterns, for 3D biomaterial deposition.
• Fabricated sample scaffolds using a micro-nozzle biomaterial deposition system for validation.

Main Results:

• Demonstrated controllable variation in pore size and porosity based on biological and mechanical requirements.
• Achieved a significant reduction in design error compared to conventional Cartesian coordinate scaffolds.
• Successfully fabricated and characterized sample scaffolds, validating the proposed methodology.

Conclusions:

• The proposed continuous tool-path planning methodology offers precise control over scaffold architecture and porosity.
• This approach enhances the fabrication of functionally gradient porous scaffolds for tissue engineering applications.
• The method reduces design errors and provides a validated pathway for advanced biomaterial deposition.