One of the major challenges in producing large scale engineered tissue is the lack of ability to create large highly perfused scaffolds in which cells can grow at a high cell density and viability. Here, we explore 3D printed polyvinyl alcohol (PVA) as a sacrificial mould in a polymer casting process. The PVA mould network defines the channels and is dissolved after curing the polymer casted around it. The printing parameters determined the PVA filament density in the sacrificial structure and this density resulted in different stiffness of the corresponding elastomer replica. It was possible to achieve 80% porosity corresponding to about 150 cm(2)/cm(3) surface to volume ratio. The process is easily scalable as demonstrated by fabricating a 75 cm(3) scaffold with about 16,000 interconnected channels (about 1m(2) surface area) and with a channel to channel distance of only 78 μm. To our knowledge this is the largest scaffold ever to be produced with such small feature sizes and with so many structured channels. The fabricated scaffolds were applied for in-vitro culturing of hepatocytes over a 12-day culture period. Smaller scaffolds (6×4 mm) were tested for cell culturing and could support homogeneous cell growth throughout the scaffold. Presumably, the diffusion of oxygen and nutrient throughout the channel network is rapid enough to support cell growth. In conclusion, the described process is scalable, compatible with cell culture, rapid, and inexpensive.

The effects of crystalline morphology and presence of nanoparticles such as cellulose nanofibers (CNFs), organically modified nanoclay (C30B), or a combination of both on water vapor sorption and diffusion in polylactide (PLA) were evaluated by a quartz spring microbalance (QSM). It was found that the large spherulite size induced by high-temperature processing leads to an increase in water sorption and a substantial reduction of diffusion with increasing crystallinity. Contrarily, small-sized spherulites, arising after low-temperature processing during solvent-casting, showed a different behavior with a slight decrease in both water vapor sorption and diffusion with increasing crystallinity. These observations suggest that solvent-casting at low temperatures should not be used to predict the properties a material will show after industrial-scale processing. From the analysis of the nanocomposite materials, it was concluded that nanoparticles affected the material′s properties not only by themselves but also by modifying the crystalline morphology. Interestingly, this led to CNF showing similar performance to C30B, decreasing water diffusivity (21 vs 27%) on isothermally crystallized materials despite its less favorable geometry. Additionally, the incorporation of 1 wt % CNF and C30B decreased water vapor transmission rate (WVTR) by 24% under an amorphous state but by 44% in a crystallized state, which makes hybrid CNF/C30B composites a promising food packaging material.