Tissue engineering scaffolds require a controlled pore size and structure to host tissue formation. Supercritical carbon dioxide (scCO2) processing may be used to form foamed scaffolds in which the escape of CO2 from a plasticized polymer melt generates gas bubbles that shape the developing pores. The process of forming these scaffolds involves a simultaneous change in phase in the CO2 and the polymer, resulting in rapid expansion of a surface area and changes in polymer rheological properties. Hence, the process is difficult to control with respect to the desired final pore size and structure. In this paper, we describe a detailed study of the effect of polymer chemical composition, molecular weight and processing parameters on final scaffold characteristics. The study focuses on poly(DL-lactic acid) (PDLLA) and poly(DL-lactic acid-co-glycolic acid) (PLGA) as polymer classes with potential application as controlled release scaffolds for growth factor delivery. Processing parameters under investigation were temperature (from 5 to 55 degrees C) and pressure (from 60 to 230 bar). A series of amorphous PDLLA and PLGA polymers with various molecular weights (from 13 KD to 96 KD) and/or chemical compositions (the mole percentage of glycolic acid in the polymers was 0, 15, 25, 35 and 50 respectively) were employed. The resulting scaffolds were characterised by optical microscopy, scanning electron microscopy (SEM), and micro X-ray computed tomography (microCT). This is the first detailed study on using these series polymers for scaffold formation by supercritical technique. This study has demonstrated that the pore size and structure of the supercritical PDLLA and PLGA scaffolds can be tailored by careful control of processing conditions.

The porous structure of a scaffold determines the ability of bone to regenerate within this environment. In situations where the scaffold is required to provide mechanical function, balance must be achieved between optimizing porosity and maximizing mechanical strength. Supercritical CO(2) foaming can produce open-cell, interconnected structures in a low-temperature, solvent-free process. In this work, we report on foams of varying structural and mechanical properties fabricated from different molecular weights of poly(DL-lactic acid) P(DL)LA (57, 25 and 15 kDa) and by varying the depressurization rate. Rapid depressurization rates produced scaffolds with homogeneous pore distributions and some closed pores. Decreasing the depressurization rate produced scaffolds with wider pore size distributions and larger, more interconnected pores. In compressive testing, scaffolds produced from 57 kDa P(DL)LA exhibited typical stress-strain curves for elastomeric open-cell foams whereas scaffolds fabricated from 25 and 15 kDa P(DL)LA behaved as brittle foams. The structural and mechanical properties of scaffolds produced from 57 kDa P(DL)LA by scCO(2) ensure that these scaffolds are suitable for potential applications in bone tissue engineering.

A hyperbranched 2-(dimethylamino)ethyl methacrylate (DMAEMA) based polymer has been synthesised by a one-pot in situ deactivation enhanced atom transfer radical polymerisation (DE-ATRP); it exhibits much higher transfection ability than linear poly(DMAEMA) and is comparable to the well known branched poly(ethylene imine) (PEI) and the SuperFect® dendrimer but with lower cytotoxicity.