3D-Printed Polycaprolactone/Hydroxyapatite Bionic Scaffold for Bone Regeneration

The limitations of traditional, autologous bone grafts, such as the scarcity of donor material and the risks of secondary surgical trauma, have spurred the development of alternatives for the repair of large bone defects. Bionic bone scaffolds fabricated via fused deposition modeling (FDM)-a three-dimensional (3D) printing technique-are considered promising. While gyroid-structured scaffolds mimic the complex micro-architecture of cancellous bone, their application in FDM 3D printing remains understudied. Furthermore, no consensus has been reached on the ideal pore size for gyroid scaffolds, which is influenced by the infill density. In this study, we fabricated five groups of polycaprolactone/hydroxyapatite (PCL/HA) scaffolds with different infill densities (40%, 45%, 50%, 55%, and 60%) using a solvent-free filament preparation method. Scanning electron microscopy (SEM) observation showed that all scaffolds exhibit an interconnected porous structure. The scaffold with the 55% infill density, featuring a pore size of 465 ± 63 μm, demonstrated optimal hydrophilicity and mechanical properties comparable to natural cancellous bone. In addition, this scaffold supported cellular bridging within its pores and showed the highest alkaline phosphatase (ALP) activity and calcium salt deposition. Our findings offer novel insights into the design of gyroid-like scaffolds and their fabrication via FDM, paving the way for potential clinical applications.