Composite materials
containing pores play a crucial role in the
field of bone tissue engineering. The nonsolvent-induced phase separation
(NIPS) technique, commonly used for manufacturing membranes, has proven
to be an effective method for fabricating composite scaffolds with
tunable porosity. To explore this potential, we produced 10% (w/v)
poly(caprolactone) (PCL)-nanohydroxyapatite (HA) composite porous
film scaffolds with varying HA contents (0/10/15/20 wt %) and two
thicknesses (corresponding to 1 and 2 mL of solution resulting in
800–900 and 1600–1800 μm thickness, respectively)
using the NIPS method. We conducted a comprehensive analysis of how
the internal microstructure and surface characteristics of these scaffolds
varied based on their composition and thickness. In particular, for
each scaffold, we analyzed overall porosity, pore size distribution,
pore shape, and degree of anisotropy as well as mechanical behaviors.
Micro-CT and SEM analyses revealed that PCL-HA scaffolds with various
HA contents possessed micro (<100 μm) scale porosity due
to the NIPS method. Greater thicknesses typically resulted in larger
average pore sizes and greater overall porosity. However, unlike in
thinner scaffolds, greater/higher HA content did not exhibit a direct
correlation with a greater pore size for thicker scaffolds. In thinner
scaffolds, adding HA above an effective threshold content of 15 wt
% and beyond did lead to a greater pore size. The higher pore anisotropy
was in line with the higher HA content for both groups. SEM images
demonstrated that both groups showed highly uniformly distributed
internal microporous morphology regardless of HA content and thickness.
The results suggest that NIPS-based scaffolds hold promise for bone
tissue engineering but that the optimal HA content and thickness should
be carefully considered based on desired porosity and application.