Mimicking the mechanical properties of native tissues is a critical criterion for an ideal tissue engineering scaffold. However, most biodegradable synthetic materials, including polyester-based polyurethanes (PUs), consist of rigid polyester chains and have high crystallinity. They typically lack the elasticity of most human tissues. In this study, a new type of biodegradable PU with excellent elasticity was synthesized based on the controlled crosslinking of poly(ester ether) triblock copolymer diols and polycaprolactone (PCL) triols using urethane linkages. Three-dimensional (3D) porous scaffolds with a defined geometry, tunable microstructures, and adjustable mechanical properties were synthesized in situ using an isocyanate-ended copolymer, a tri-armed PCL, and a chain extender. The mechanical properties of the scaffolds can be easily tuned by changing the ratio of reactants, varying the solution concentration, or using a porogen. Notably, all of these scaffolds, although mostly made of rigid PCL chains, showed remarkable elasticity and cyclical properties. With an optimized molecular design, a maximum recovery rate of 99.8% was achieved. This was because the copolymer provided molecular flexibility while the long chain crosslinking of PCL triol hindered crystallization, thus making the PU behave like an amorphous elastic material. Moreover, the in vitro cell culture of 3T3 fibroblasts and MG63 osteoblast-like cells confirmed the biocompatibility of these PU scaffolds and revealed that scaffolds with different stiffnesses can stimulate the proliferation of different types of cells. All of these attributes make PU scaffolds extremely suitable for the regeneration of tissues that experience dynamic loading.

Ultra‐high‐molecular weight polyethylene (UHMWPE) powder was processed using injection molding (IM) with different cavity thicknesses and injection‐compression molding (ICM). The processing parameters of feeding the powders were optimized to ensure proper dosage and avoid jeopardizing the UHMWPE molecular structure. Dynamic mechanical analysis (DMA) and Fourier‐transform infrared spectroscopy tests confirmed that the thermal and oxidative degradations of the material were avoided but crosslinking was induced during melt processing. Tensile tests and impact tests showed that the ICM samples were superior to those of IM. Increased cavity thickness and ICM were helpful for reducing the injection pressure and improving the mechanical properties due to effective packing of the material. Short shot molding showed that the UHMWPE melt did not exhibit the typical progressive and smooth melt front advancements. Due to its highly entangled polymer chains structure, it entered the cavity as an irregular porous‐like structure, as shown by short shots and micro‐computed tomography scans. A delamination skin layer (around 300‐μm thick and independent of cavity thickness) was formed on all IM sample surfaces while it was absent in the ICM samples, suggesting two different flow behaviors between IM and ICM during the packing phase. POLYM. ENG. SCI., 59:E170–E179, 2019. © 2018 Society of Plastics Engineers

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