Toward 4D Biomaterials: Comparing Electrospun and 3D-Printed Shape-Memory Scaffolds

Background/Objectives: Shape-memory biodegradable scaffolds (4D scaffolds) represent promising platforms for minimally invasive tissue engineering and localized drug delivery. This study investigated how two different fabrication techniques, electrospinning (ES) and extrusion-based direct ink writing (DIW), influence the structural, thermal, mechanical, shape-memory, and drug-release properties of poly(L-lactide-co-caprolactone) (PLA/PCL 70:30) scaffolds loaded with dexamethasone (DXM). Methods: DXM-loaded PLA/PCL 70:30 scaffolds were fabricated by ES and DIW. The resulting matrices were characterized in terms of morphology, mass, thickness, drug-loading efficiency, thermal properties by differential scanning calorimetry, shape-memory performance, tensile mechanical properties, and in vitro DXM release. Results: Both fabrication techniques produced DXM-loaded matrices with comparable mass and thickness and high loading efficiencies (>82%). Glass transition temperatures ranged between 33 and 39 °C, supporting thermally induced shape recovery under physiologically relevant conditions, while ES processing was associated with higher polymer crystallinity. All scaffolds exhibited shape-memory behavior, with recovery ratios exceeding 90%. ES scaffolds displayed a microporous nanofibrous architecture, whereas DIW scaffolds showed a more open and highly porous structure. These morphological differences were reflected in their mechanical behavior: ES scaffolds exhibited higher tensile strength (up to 16.5 MPa vs. 1.9 MPa) and elongation at break (up to 320% vs. 243%). Drug-release profiles were also fabrication-dependent, with ES scaffolds reaching a plateau at approximately 80% DXM release, whereas DIW scaffolds showed near-complete release within 48 h. Conclusions: Both fabrication approaches preserved the thermoresponsive shape-memory behavior of PLA/PCL 70:30 but generated distinct scaffold architectures that strongly influenced mechanical performance and DXM-release kinetics.