Fabrication of tissue engineering scaffolds through solid-state foaming of immiscible polymer blends

In scaffold-based tissue engineering, the fabrication process is important for producing suitable microstructures for seeded cells to grow and reformulate. In this paper, we present a new approach to scaffold fabrication by combining the solid-state foaming and the immiscible polymer-blending method. The proposed approach has the advantage of being versatile and able to create a wide range of pore size and porosity. The proposed method is studied with polylactic acid (PLA) and polystyrene (PS) blends. The interconnected porous structure was created by first foaming the PLA/PS blend and then extracting the PS phase. The solid-state foaming experiments were conducted under various conditions to achieve the desired pore sizes. It is shown that the PS phase of the PLA/PS blend can be extracted much faster in the foamed samples and the pore size of the scaffolds can be easily controlled with proper gas foaming parameters. The average pore size achieved in the foaming process ranged from 20 to 70 µm. After PS extraction, both pore size and porosity can be further improved. For example, the pore size and porosity increased from 48 µm and 49% to 59 µm and 67%, respectively, after the PS extraction process. The fabricated porous scaffolds were used to culture human osteoblast cells. Cells grew well and gradually formed a fibrous structure. The combined solid-state foaming and immiscible polymer blending method provides a new technique for fabricating tissue-engineering scaffolds.