Bone implants or replacements are very scarce due to the low donor availability and the high rate of body rejection. For this reason, tissue engineering strategies have been developed as alternative solutions to this problem. This research sought to create a cellular scaffold with an intricate and complex network of interconnected pores and microchannels using salt leaching and additive manufacturing (3D printing) methods that mimic the hierarchical internal structure of the bone. A biocompatible hydrogel film (based on poly-ethylene glycol) was used to cover the surface of different polymeric scaffolds. This thin film was then exposed to various stimuli to spontaneously form wrinkled micropatterns, with the aim of increasing the contact area and the material’s biocompatibility. The main innovation of this study was to include these wrinkled micropatterns on the surface of the scaffold by taking advantage of thin polymer film surface instabilities. On the other hand, salt and nano-hydroxyapatite (nHA) particles were included in the polymeric matrix to create a modified filament for 3D printing. The printed part was leached to eliminate porogen particles, leaving homogenously distributed pores on the structure. The pores have a mean size of 26.4 ± 9.9 μm, resulting in a global scaffold porosity of ~42% (including pores and microchannels). The presence of nHA particles, which display a homogeneous distribution according to the FE-SEM and EDX results, have a slight influence on the mechanical resistance of the material, but incredibly, despite being a bioactive compound for bone cells, did not show a significant increase in cell viability on the scaffold surface. However, the synergistic effect between the presence of the hydrogel and the pores on the material does produce an increase in cell viability compared to the control sample and the bare PCL material.

Multifunctional scaffolds that combine structural support with the controlled delivery of bioactive agents remain a major challenge in tissue engineering. To extend the use of these devices in biomedicine, 3D printing is presented as an alternative that enables the manufacture of complex devices tailored to each patient, thereby solving specific problems in a timely and efficient manner. In this study, porous 3D scaffolds were fabricated via digital light processing (DLP) using a PET-RAFT resin composed of 2-(dimethylamino)ethyl methacrylate (DMAEMA) and poly(ethylene glycol) diacrylate (PEGDA₅₇₅). Sodium chloride (NaCl) was incorporated as a porogen, while insulin-loaded poly(lactic-co-glycolic acid) (PLGA) nanoparticles were embedded as osteoinductive agents. The printed constructs exhibited high-resolution, reproducible trabecular-like architectures, as confirmed by micro-computed tomography (micro-CT), with interconnected pores averaging 70.7 ± 24.7 μm and a total porosity of 57.0 ± 6.98%. Thermal and chemical analyses confirmed scaffold stability and controlled degradability. Cytocompatibility assays using MC3T3-E1, C2C12, hGMSCs, and C166-GFP cells showed viability above 80% after 7 days (ISO 10993-5). Insulin-loaded nanoparticles enabled sustained release, characterized by an initial burst followed by gradual release up to 72 h. Dynamic bioreactor culture enhanced cell adhesion and RUNX2 expression, confirming the osteoinductive potential of the hybrid scaffold for advanced BTE applications. This study introduces an innovative PET-RAFT-derived resin that combines structural reinforcement with spatiotemporal regulation of insulin release, offering a potential strategy for enhanced biomaterial tissue engineering and tailored therapeutic interventions.