Fabrication of hydroxyapatite-poly(ε-caprolactone) scaffolds by a combination of the extrusion and bi-axial lamination processes

Hydroxyapatite (HA)/poly(ε-caprolactone) (PCL) composite scaffolds were fabricated using a combination of the extrusion and bi-axial lamination processes. Firstly, HA/PCL composites with various HA contents (0, 50, 60, 70 wt%) were prepared by mixing the HA powders and the molten PCL at 100°C and then extruded through an orifice with dimensions of 600 × 600 μm to produce HA/PCL composite fibers. Isobutyl methacrylate (IBMA) polymer fiber was also prepared in a similar manner for use as a fugitive material. The 3-D scaffold was then produced by the bi-axial lamination of the HA/PCL and IBMA fibers, followed by solvent leaching to remove the IBMA. It was observed that the HA/PCL composites had a superior elastic modulus and biological properties, as compared to the pure PCL. The fabricated HA/PCL scaffold showed a controlled pore structure (porosity of ∼49% and pore size of ∼512 μm) and excellent welding between the HA/PCL fibers, as well as a high compressive strength of ∼7.8 MPa.