Design of porous three-dimensional PDLLA/nano-hap composite scaffolds using stereolithography

PURPOSE: The stereolithography process is based on the photopolymerization through a dynamic mask generator of successive layers of photocurable resin, allowing the manufactory of accurate micro objects with high aspect ratio and curved surfaces. In the present work the stereolithography technique is applied to produce nanocomposite bioactive scaffolds from Computer Assisted Design (CAD) files. METHODS: Porous scaffolds are designed with computer software and built with a composite poly(D,L-lactide)/nano hydroxyapatite based resin. Triply-periodic minimal surfaces are shown to be a more versatile source of biomorphic scaffold designs and scaffolds with Double Gyroid architecture are realized and characterized from morphological, mechanical and biological point of view. RESULTS: The structures show excellent reproduction of the design and good mechanical properties. Human marrow mesenchimal cells (hMSC) are seeded onto porous PDLLA composites for 3 weeks and cultured in osteogenic medium. Presence of nano-hap seems to increase the mechanical properties without affecting the morphology of the structures. The composite Double Gyroid scaffolds exhibit good biocompatibility and confirm that nano-hap enhances the scaffold bioactive and osteoconductive potential. CONCLUSION: The presented technology and materials enable an accurate preparation of tissue engineering composite scaffolds with a large freedom of design, and really complex internal architectures. Results indicate that the scaffolds fulfill the basic requirements of bone tissue engineering scaffold, and have the potential to be applied in orthopedic surgery.