Tuning the three-dimensional architecture of supercritical CO2 foamed PCL scaffolds by a novel mould patterning approach

In tissue engineering, the use of supercritical CO2 foaming is a valuable and widespread choice to design and fabricate porous bioactive scaffolds for cells culture and new tissue formation in three dimensions. Nevertheless, the control of scaffold pores size, shape and spatial distribution with foaming technique remains, to date, a critical limiting step. To mimic the biomimetic structure of tissues like bone, blood vessels and nerve tissues, we developed a novel supercritical CO2-foaming approach for the preparation of dual-scale, dual-shape porous polymeric scaffolds with pre-defined arrays of micro-channels within a foamed porosity. The scaffolds were prepared by foaming the polymer inside polytetrafluoroethylene moulds having precisely designed arrays of pillars and obtained by computer-aided micromachining technique. Polycaprolactone was chosen as model polymer for scaffolds fabrication and the effect of mould patterning and scCO2 foaming conditions on scaffolds morphology, structural properties and biocompatibility was addressed and discussed.