Polyhydroxyalkanoates are biopolyesters whose biocompatibility, biodegradability, environmental sustainability, processing versatility, and mechanical properties make them unique scaffolding polymer candidates for tissue engineering. The development of innovative biomaterials suitable for advanced Additive Manufacturing (AM) offers new opportunities for the fabrication of customizable tissue engineering scaffolds. In particular, the blending of polymers represents a useful strategy to develop AM scaffolding materials tailored to bone tissue engineering. In this study, scaffolds from polymeric blends consisting of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) and poly(D,L-lactide-co-glycolide) (PLGA) were fabricated employing a solution-extrusion AM technique, referred to as Computer-Aided Wet-Spinning (CAWS). The scaffold fibers were constituted by a biphasic system composed of a continuous PHBV matrix and a dispersed PLGA phase which established a microfibrillar morphology. The influence of the blend composition on the scaffold morphological, physicochemical, and biological properties was demonstrated by means of different characterization techniques. In particular, increasing the content of PLGA in the starting solution resulted in an increase in the pore size, the wettability, and the thermal stability of the scaffolds. Overall, in vitro biological experiments indicated the suitability of the scaffolds to support murine preosteoblast cell colonization and differentiation towards an osteoblastic phenotype, highlighting higher proliferation for scaffolds richer in PLGA.

Additive manufacturing (AM) is rapidly advancing, particularly in biomedical applications, necessitating a deeper understanding of the mechanical behavior of 3D-printed materials. Structures created using fused deposition modeling (FDM) exhibit anisotropic properties due to fabrication inhomogeneity and material architecture. Finite element modeling (FEM) is commonly used to predict mechanical behavior, though studies on porous structures have not deeply investigated the influence of geometrical features on global mechanical behavior. This study aimed to correlate the mechanical properties of porous polylactic acid scaffolds with different patterns and infill densities, fabricated via AM through the synergies of experimental and computational approaches. Tensile testing and FEM simulations were conducted, revealing differences in elastic modulus and tensile strength based on infill orientation. A sensitivity analysis on the main geometrical features assessed variations in filament dimensions and layer spacing. FEM simulations showed strong agreement with experimental data, validating their predictive capability, with deviations due to minor structural defects and irregularities in the extruded filaments. This study established for the first time the influence of geometrical details on the elastic properties of porous scaffolds, opening up to new tailored design for, but not limited to, biomedical applications.

Poly(lactide) (PLA) is one of the most investigated semicrystalline polymers for material extrusion (MEX) additive manufacturing (AM) techniques based on polymer melt processing. Research on its application for the development of customized devices tailored to specific anatomical parts of the human body can provide new personalized medicine strategies. This research activity was aimed at testing a new multifunctional AM system for the design and fabrication by MEX of anatomical and dog-bone-shaped PLA samples with different infill densities and deposition angles. In particular, a commercial PLA filament was employed to validate the computer-aided design (CAD) and manufacturing (CAM) process for the development of scaffold prototypes modeled on a human bone defect. Physical-chemical characterization of the obtained samples by ¹H-NMR spectroscopy, size exclusion chromatography (SEC), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC) demonstrated a small reduction of polymer molecular weight (~5%) due to thermal processing, as well as that the commercial polymer employed was a semicrystalline poly(d,l-lactide). Mechanical characterization highlighted the possibility of tuning elastic modulus and strength, as well as the elongation at break up to a 60% value by varying infill parameters.