Microstructural Characterization of PCL-HA Bone Scaffolds Based on Nonsolvent-Induced Phase Separation

Composite materials containing pores play a crucial role in the field of bone tissue engineering. The nonsolvent-induced phase separation (NIPS) technique, commonly used for manufacturing membranes, has proven to be an effective method for fabricating composite scaffolds with tunable porosity. To explore this potential, we produced 10% (w/v) poly(caprolactone) (PCL)-nanohydroxyapatite (HA) composite porous film scaffolds with varying HA contents (0/10/15/20 wt %) and two thicknesses (corresponding to 1 and 2 mL of solution resulting in 800-900 and 1600-1800 μm thickness, respectively) using the NIPS method. We conducted a comprehensive analysis of how the internal microstructure and surface characteristics of these scaffolds varied based on their composition and thickness. In particular, for each scaffold, we analyzed overall porosity, pore size distribution, pore shape, and degree of anisotropy as well as mechanical behaviors. Micro-CT and SEM analyses revealed that PCL-HA scaffolds with various HA contents possessed micro (<100 μm) scale porosity due to the NIPS method. Greater thicknesses typically resulted in larger average pore sizes and greater overall porosity. However, unlike in thinner scaffolds, greater/higher HA content did not exhibit a direct correlation with a greater pore size for thicker scaffolds. In thinner scaffolds, adding HA above an effective threshold content of 15 wt % and beyond did lead to a greater pore size. The higher pore anisotropy was in line with the higher HA content for both groups. SEM images demonstrated that both groups showed highly uniformly distributed internal microporous morphology regardless of HA content and thickness. The results suggest that NIPS-based scaffolds hold promise for bone tissue engineering but that the optimal HA content and thickness should be carefully considered based on desired porosity and application.