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Design and Development of Porous Scaffolds

Forming porous structures is useful in many applications including tissue regeneration, and three-dimensional cell cultures. An important requirement is promoting biological activity. Porous structures generated from natural and synthetic polymers or after removing the cellular components from xenogeneic tissues have been used to support and guide the in-growth of cells. A majority of the clinical success in tissue regeneration has been accomplished using substitutes derived from various tissues such skin, arteries, veins, or xenogeneic sources. Examples include small intestinal submucosa (SIS), acellular dermis or porcine pericardium. SIS is unique from other acellular matrices as it contains growth factors. While using naturally formed structures one concern is heterogeneity in source (microstructure of SIS from different regions are shown below) and physicochemical characteristics. Hence, manufacturing porous templates using pure components allows formation of matrices with required features in addition to large scale production.

 

   

 
      Scaffolds have been generated from synthetic and natural polymers using various techniques such as controlled rate freezing and lyophilization, porogen-leaching technique, free-form printing and electrospraying. Each technique has advantages and disadvantages and many not be suitable for all polymers. In addition, developing porous structures using pure components may not be useful as these pure components do not recreate all the necessary functionalities such as regulation on cellular activity, weak mechanical strength and inadequate tailorability to alter mechanical and degradation properties. Combining two different polymers is an attractive option to take advantage of their positive characteristics and wealth of previous literature. A significant challenge in combining different polymers is the chemistry of the two systems. For example, PLGA (or PCL) is typically dissolved in halogenated hydrocarbons (chloroform, methylene chloride, etc) which are hydrophobic and sparingly miscible in acidic water, the solvent used for dissolving natural polymers. Chemically bonding natural polymers (a classical example is heparin conjugation) to other substrate results in loss of bioregulation.  
The overall goal of this project is to develop technologies that produce three dimensional porous matrices with well controlled and defined features, useful in large scale regeneration of tissues. Our group focuses on innovative methods of dispersing the two polymeric systems without chemically conjugating them with complex reaction mechanisms. We work on generating scaffolds from blends of natural and synthetic polymers, based on the designed characteristics of natural matrixes which have shown some clinical success. Controlled rate freezing and lypohilization (shown in the figure below) technique is the method of choice while forming scaffolds from natural polymers such as chitosan and collagen, which dissolve in acidic water.  
 
An additional method is electrospraying, a widely established polymer processing technology which allows generation of fibers in nanometer to micrometer size, similar to that found in the body. We have formed a) emulsion systems, b) physically forcing synthetic and natural polymers to co-exist, c) developing a unique solvent mixture that can dissolve both natural polymers (gelatin, chitosan, or collagen) and synthetic PCL, or d) forming reinforced composite systems. The composite matrix consists of two porous compartments of natural polymers (chitosan/gelatin) reinforced with a thin membrane of synthetic polymers (PLGA or PCL). These approaches inherently possess easy tailorability of mechanical properties, permeability, pore size, degradation characteristics, and biological activity. We also work on delivering growth factors using nanoparticles (shown in the figure below) to create a heterogeneous environment that could support the differentiation of stem cells into needed cell types. We perform a wide variety of mechanical testing analyses including tensile, compression, cyclical, stress relaxation testing under physiological conditions and evaluate various mechanical properties. These properties are compared with natural tissues to assess their use. We also model the mechanical behavior using concepts developed in biomechanics such as the viscoelastic behavior using quasi linear viscoelastic models or various combination of spring and dashpots using a proprietary code developed by Dr. R Russell Rhinehart (Chem Engineering, Oklahoma State University) in MS Exel.  
 

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