Biphasic osteochondral scaffold fabrication using multi-material mask projection stereolithography

Abstract

Purpose

This study aims to develop a multi-material stereolithography (MMSL) technique to directly fabricate a biphasic osteochondral scaffold.

Design/methodology/approach

A bespoke prototype MMSL system was developed based on a bottom-up mask projection approach. The system was controlled by a multi-material fabrication algorithm with minimum number of switching cycles during fabrication. A variable-power light source was used to fabricate materials with significantly different curing characteristics. The light-curable poly(ethylene glycol) diacrylate (PEGDA) hydrogel and beta-tricalcium phosphate (β-TCP) ceramic suspension were used for fabricating the biphasic osteochondral scaffold.

Findings

The bonding strength of the multi-material interface is shown to be mainly affected by the type of photopolymer, rather than the switching of the materials in MMSL. Lighting power densities of 2.64 and 14.98 mW/cm2 were used for curing the PEGDA hydrogel and the ß-TCP ceramic suspension, respectively. A biphasic osteochondral scaffold with complex interface was successfully fabricated.

Originality/value

This study proposes a potential technical method (MMSL) for manufacturing a complex biphasic osteochondral scaffold composing a PEGDA hydrogel/ß-TCP ceramic composite in a time-efficient and precise manner. The designed bone-cartilage scaffold interface and the surface of the cartilage scaffold can be precisely manufactured.

Citation

Wu, X., Lian, Q., Li, D. and Jin, Z. (2019), "Biphasic osteochondral scaffold fabrication using multi-material mask projection stereolithography", Rapid Prototyping Journal, Vol. 25 No. 2, pp. 277-288. https://doi.org/10.1108/RPJ-07-2017-0144