Hierarchically porous bone scaffold fabricated via direct foam writing with TCP/ZrO2 composite ink

Customizing bone scaffolds to mimic the hierarchically porous structure of natural bone presents a promising strategy for treating critical bone defects. Although low-cost direct ink writing (DIW) is often used to customize bone scaffolds, the limited print resolution made it difficult to print microporous structures. In this study, DIW was combined with the direct foam method to construct bone scaffolds with hierarchical and interconnected macro-micro porous structures. The foam stabilization mechanism of pure TCP was investigated to prepare TCP-enhanced ZrO2-based composite foam inks. Incorporating TCP endowed a richer interconnection structure to the composite foam. The printed bone scaffolds feature three scales of pore structure: interconnected macropores of 400-500 mu m, bubble template pores of 50 mu m, and open pores of <20 mu m. The scaffold exhibited properties comparable to cancellous bone, such as 90 % porosity, 3.1 MPa compressive strength, and 1.0 GPa elastic modulus. In vitro experiments have demonstrated that cells can grow into the interior of the scaffold by following the connecting pores. And, incorporating TCP significantly enhances osteogenic protein and gene expression in bionic bone scaffolds. This facile and controllable approach offers an alternative solution to addressing the challenge of clinical implant shortages.