Artificial scaffolds play vital roles in tissue engineering as they provide a supportive environment for cell attachment, proliferation and differentiation during tissue formation. Fabrication of tissue scaffolds is thus of fundamental importance for tissue engineering. Of the variety of scaffold fabrication techniques available, rapid prototyping (RP) methods have attracted a great deal of attention in recent years. This method can improve conventional scaffold fabrication by controlling scaffold microstructure, incorporating cells into scaffolds and regulating cell distribution. All of these contribute towards the ultimate goal of tissue engineering: functional tissues or organs. Dispensing is typically used in different RP techniques to implement the layer-by-layer fabrication process. This article reviews RP methods in tissue scaffold fabrication, with emphasis on dispensing-based techniques, and analyzes the effects of different process factors on fabrication performance, including flow rate, pore size and porosity, and mechanical cell damage that can occur in the bio-manufacturing process.

Mixtures of alginate and hydroxyapatite (HA) are promising materials for biomedical applications such as the fabrication of tissue scaffolds. In this paper, the flow behavior of alginate/HA mixtures was investigated and determined to be dependent on the concentration of both alginate and HA, and temperature. The relationships were mathematically established and verified with experimental results. As applied to the tissue scaffold fabrication, the flow rate of the biomaterial solution was predicted from the established flow behavior and verified by experiments. On this basis, the moving speed of the needle was determined and used in the tissue scaffold fabrication. The results obtained show that the knowledge of the flow behavior is essential to the fabrication of tissue scaffolds with an interconnected microstructure.

Engineered scaffolds have been shown to be critical to various tissue engineering applications. This paper presents the development of a novel three-dimensional scaffold made from a mixture of chitosan microspheres (CMs) and poly(L-lactide) by means of the rapid freeze prototyping (RFP) technique. The CMs were used to encapsulate bovine serum albumin (BSA) and improve the scaffold mechanical properties. Experiments to examine the BSA release were carried out; the BSA release could be controlled by adjusting the crosslink degree of the CMs and prolonged after the CMs were embedded into the PLLA scaffolds, while the examination of the mechanical properties of the scaffolds illustrates that they depend on the ratio of CMs to PLLA in the scaffolds as well as the cryogenic temperature used in the RFP fabrication process. The chemical characteristics of the PLLA/chitosan scaffolds were evaluated by Fourier transform infrared (FTIR) spectroscopy. The morphological and pore structure of the scaffolds were also examined by scanning electron microscopy and micro-tomography. The results obtained show that the scaffolds have higher porosity and enhanced pore size distribution compared to those fabricated by the dispensing-based rapid prototyping technique. This study demonstrates that the novel scaffolds have not only enhanced porous structure and mechanical properties but also showed the potential to preserve the bioactivities of the biomolecules and to control the biomolecule distribution and release rate.