Large-scale production of 3D bioactive glass macroporous scaffolds for tissue engineering

For tissue engineering applications, a scaffold is required that can act as a template and guide for cell proliferation, cell differentiation and tissue growth. Interconnected pores with diameters greater than 100 mum are required for tissue ingrowth, vascularisation and nutrient delivery to the centre of the scaffold. 3D bioactive glass scaffolds have been produced, by foaming sol-gel derived bioactive glasses. The method to produce foams with a modal macropore diameter of 100 mum, and a handling strength suitable for cell culture, was to foam 50 ml batches of sol with the aid of a surfactant and gelling agent. In vitro and in vivo tests show that the scaffolds have high potential to be used in bone tissue engineering applications. Larger batches are required to produce scaffolds commercially. The aim of this work was to investigate how the process could be up-scaled for commercial use. This study shows that foaming larger aliquots of sol decreased the scaffold porosity and interconnectivity and investigates methods of modifying the process to obtain large quantities of foam scaffolds with pores in excess of 100 mum. The optimum method to produce foams of similar pore structure from 200 ml sol to those produced from 50 ml sol comprised of adding 3 ml surfactant and 12 ml dionised water to the sol to start foaming and injecting a gas mixture (70% helium, 30% nitrogen) at 0.2 bar while applying vigorous agitation.