In this paper, the use of the Selective Laser Sintering (SLS) process for the generation of bone tissue engineering scaffolds from PCL and PCL/TCP is explored. Different scaffold designs are generated and are assessed from the point of view of manufacturability, porosity and mechanical performance. Large scaffold specimens are generated, with a preferred design, and are assessed through an in vivo study in a critical size bone defect in the sheep tibia with subsequent microscopic, histological and mechanical evaluation. Further explorations are performed to generate scaffolds with increasing TCP contents.Scaffold fabrication from PCL and PCL/TCP mixtures with up to 50 mass-% TCP is shown to be possible. With increasing macroporosity the stiffness of the scaffolds is seen to drop, however, the stiffness can be increased by minor geometrical changes, such as the addition of a cage around the scaffold. In the animal study the selected scaffold for implantation did not perform as well as the TCP control in terms of new bone formation and the resulting mechanical performance of the defect area. A possible cause for this is presented.