Amalie E. Donius

Biomaterials by freeze casting

The functional requirements for synthetic tissue substitutes appear deceptively simple: they should provide a porous matrix with interconnecting porosity and surface properties that promote rapid tissue ingrowth; at the same time, they should possess sufficient stiffness, strength and toughness to prevent crushing under physiological loads until full integration and healing are reached. Despite extensive efforts and first encouraging results, current biomaterials for tissue regeneration tend to suffer common limitations: insufficient tissue–material interaction and an inherent lack of strength and toughness associated with porosity. The challenge persists to synthesize materials that mimic both structure and mechanical performance of the natural tissue and permit strong tissue–implant interfaces to be formed. In the case of bone substitute materials, for example, the goal is to engineer high-performance composites with effective properties that, similar to natural mineralized tissue, exceed by orders of magnitude the properties of its constituents. It is still difficult with current technology to emulate in synthetic biomaterials multi-level hierarchical composite structures that are thought to be the origin of the observed mechanical property amplification in biological materials. Freeze casting permits to manufacture such complex, hybrid materials through excellent control of structural and mechanical properties. As a processing technique for the manufacture of biomaterials, freeze casting therefore has great promise.

Structure-property-processing correlations in freeze-cast composite scaffolds.

Surprisingly few reports have been published, to date, on the structure-property-processing correlations observed in freeze-cast materials directionally solidified from polymer solutions, or ceramic or metal slurries. The studies that exist focus on properties of sintered ceramics, that is materials whose structure was altered by further processing. In this contribution, we report first results on correlations observed in alumina-chitosan-gelatin composites, which were chosen as a model system to test and compare the effect of particle size and processing parameters on their mechanical properties at a specific composition. Our study reveals that highly porous (>90%) hybrid materials can be manufactured by freeze casting, through the self-assembly of a polymer and a ceramic phase that occurs during directional solidification, without the need of additional processing steps such as sintering or infiltration. It further illustrates that the properties of freeze-cast hybrid materials can independently be tailored at two levels of their structural hierarchy, allowing for the simultaneous optimization of both mechanical and structural requirements. An increase in freezing rate resulted in decreases in lamellar spacing, cell wall thickness, pore aspect ratio and cross-sectional area, as well as increases in both Youngs modulus and compressive yield strength. The mechanical properties of the composite scaffolds increased with an increasing particle size. The results show that both structure and mechanical properties of the freeze-cast composites can be custom-designed and that they are thus ideally suited for a large variety of applications that require high porosity at low or medium load-bearing capacity.

Superior mechanical performance of highly porous, anisotropic nanocellulose–montmorillonite aerogels prepared by freeze casting

Directionally solidified nanofibrillated cellulose (NFC)-sodium-montmorillonite (MMT) composite aerogels with a honeycomb-like pore structure were compared with non-directionally frozen aerogels with equiaxed pore structure and identical composition and found to have superior functionalities. To explore structure-property correlations, three different aerogel compositions of 3wt% MMT, and 0.4wt%, 0.8wt%, and 1.2wt% NFC, respectively, were tested. Young׳s modulus, compressive strength and toughness were found to increase with increasing NFC content for both architectures. The modulus increased from 25.8kPa to 386kPa for the isotropic and from 2.13MPa to 3.86MPa for the anisotropic aerogels, the compressive yield strength increased from 3.3kPa to 18.0kPa for the isotropic and from 32.3kPa to 52.5kPa for the anisotropic aerogels, and the toughness increased from 6.3kJ/m(3) to 24.1kJ/m(3) for the isotropic and from 22.9kJ/m(3) to 46.2kJ/m(3) for the anisotropic aerogels. The great range of properties, which can be achieved through compositional as well as architectural variations, makes these aerogels highly attractive for a large range of applications, for which either a specific composition, or a particular pore morphology, or both are required. Finally, because NFC is flammable, gasification experiments were performed, which revealed that the inclusion of MMT increased the heat endurance and shape retention functions of the aerogels dramatically up to 800°C while the mechanical properties were retained up to 300°C.

An ice-templated, linearly aligned chitosan-alginate scaffold for neural tissue engineering

Several strategies have been investigated to enhance axonal regeneration after spinal cord injury, however, the resulting growth can be random and disorganized. Bioengineered scaffolds provide a physical substrate for guidance of regenerating axons towards their targets, and can be produced by freeze casting. This technique involves the controlled directional solidification of an aqueous solution or suspension, resulting in a linearly aligned porous structure caused by ice templating. In this study, freeze casting was used to fabricate porous chitosan-alginate (C/A) scaffolds with longitudinally oriented channels. Chick dorsal root ganglia explants adhered to and extended neurites through the scaffold in parallel alignment with the channel direction. Surface adsorption of a polycation and laminin promoted significantly longer neurite growth than the uncoated scaffold (poly-L-ornithine + Laminin = 793.2 ± 187.2 μm; poly-L-lysine + Laminin = 768.7 ± 241.2 μm; uncoated scaffold = 22.52 ± 50.14 μm) (P < 0.001). The elastic modulus of the hydrated scaffold was determined to be 5.08 ± 0.61 kPa, comparable to reported spinal cord values. The present data suggested that this C/A scaffold is a promising candidate for use as a nerve guidance scaffold, because of its ability to support neuronal attachment and the linearly aligned growth of DRG neurites.

New crosslinkers for electrospun chitosan fibre mats. I. Chemical analysis

Chitosan (CS), the deacetylated form of chitin, the second most abundant, natural polysaccharide, is attractive for applications in the biomedical field because of its biocompatibility and resorption rates, which are higher than chitin. Crosslinking improves chemical and mechanical stability of CS. Here, we report the successful utilization of a new set of crosslinkers for electrospun CS. Genipin, hexamethylene-1,6-diaminocarboxysulphonate (HDACS) and epichlorohydrin (ECH) have not been previously explored for crosslinking of electrospun CS. In this first part of a two-part publication, we report the morphology, determined by field emission scanning electron microscopy (FESEM), and chemical interactions, determined by Fourier transform infrared microscopy, respectively. FESEM revealed that CS could successfully be electrospun from trifluoroacetic acid with genipin, HDACS and ECH added to the solution. Diameters were 267 ± 199 nm, 644 ± 359 nm and 896 ± 435 nm for CS–genipin, CS–HDACS and CS–ECH, respectively. Short- (15 min) and long-term (72 h) dissolution tests (T600) were performed in acidic, neutral and basic pHs (3, 7 and 12). Post-spinning activation by heat and base to enhance crosslinking of CS–HDACS and CS–ECH decreased the fibre diameters and improved the stability. In the second part of this publication, we report the mechanical properties of the fibres.

New crosslinkers for electrospun chitosan fibre mats. Part II: mechanical properties

Few studies exist on the mechanical performance of crosslinked electrospun chitosan (CS) fibre mats. In this study, we show that the mat structure and mechanical performance depend on the different crosslinking agents genipin, epichlorohydrin (ECH), and hexamethylene-1,6-diaminocarboxysulphonate (HDACS), as well as the post-electrospinning heat and base activation treatments. The mat structure was imaged by field emission scanning electron microscopy and the mechanical performance was tested in tension. The elastic modulus, tensile strength, strain at failure and work to failure were found to range from 52 to 592 MPa, 2 to 30 MPa, 2 to 31 per cent and 0.041 to 3.26 MJ m−3, respectively. In general, neat CS mats were found to be the stiffest and the strongest, though least ductile, while CS–ECH mats were the least stiff, weakest, but the most ductile, and CS–HDACS fibre mats exhibited intermediary mechanical properties. The mechanical performance of the mats is shown to reflect differences in the fibre diameter, number of fibre–fibre contacts formed within the mat, as well as varying intermolecular bonding and moisture content. The findings reported here complement the chemical properties of the mats, described in part I of this study.

Osteoblast biocompatibility of premineralized, hexamethylene-1,6-diaminocarboxysulfonate crosslinked chitosan fibers.

Biopolymer-ceramic composites are thought to be particularly promising materials for bone tissue engineering as they more closely mimic natural bone. Here, we demonstrate the fabrication by electrospinning of fibrous chitosan-hydroxyapatite composite scaffolds with low (1 wt %) and high (10 wt %) mineral contents. Scanning electron microscopy (FESEM), energy dispersive spectroscopy (EDS) and unidirectional tensile testing were performed to determine fiber surface morphology, elemental composition, and tensile Youngs modulus (E) and ultimate tensile strength (σUTS ), respectively. EDS scans of the scaffolds indicated that the fibers, crosslinked with either hexamethylene-1,6-diaminocarboxysulfonate (HDACS) or genipin, have a crystalline hydroxyapatite mineral content at 10 wt % additive. Moreover, FESEM micrographs showed that all electrospun fibers have diameters (122-249 nm), which fall within the range of those of fibrous collagen found in the extracellular matrix of bone. Youngs modulus and ultimate tensile strength of the various crosslinked composite compositions were in the range of 116-329 MPa and 2-15 MPa, respectively. Osteocytes seeded onto the mineralized fibers were able to demonstrate good biocompatibility enhancing the potential use for this material in future bone tissue engineering applications.

Strategies for neurotrophin-3 and chondroitinase ABC release from freeze-cast chitosan–alginate nerve-guidance scaffolds

Freeze casting, or controlled unidirectional solidification, can be used to fabricate chitosan–alginate (C–A) scaffolds with highly aligned porosity that are suitable for use as nerve‐guidance channels. To augment the guidance of growth across a spinal cord injury lesion, these scaffolds are now evaluated in vitro to assess their ability to release neurotrophin‐3 (NT‐3) and chondroitinase ABC (chABC) in a controlled manner. Protein‐loaded microcapsules were incorporated into C–A scaffolds prior to freeze casting without affecting the original scaffold architecture. In vitro protein release was not significantly different when comparing protein loaded directly into the scaffolds with release from scaffolds containing incorporated microcapsules. NT‐3 was released from the C–A scaffolds for 8 weeks in vitro, while chABC was released for up to 7 weeks. Low total percentages of protein released from the scaffolds over this time period were attributed to limitation of diffusion by the interpenetrating polymer network matrix of the scaffold walls. NT‐3 and chABC released from the scaffolds retained bioactivity, as determined by a neurite outgrowth assay, and the promotion of neurite growth across an inhibitory barrier of chondroitin sulphate proteoglycans. This demonstrates the potential of these multifunctional scaffolds for enhancing axonal regeneration through growth‐inhibiting glial scars via the sustained release of chABC and NT‐3. Copyright

Osteoblast biocompatibility of novel chitosan crosslinker, hexamethylene-1,6-diaminocarboxysulfonate

Chitosan is a naturally occurring polysaccharide, which has proven to be an attractive candidate for bone tissue engineering, due to its ability to promote osteoblast mineralization. Electrospinning has become a well-established cell scaffold processing technique, as it produces a high surface area to volume fibrous material that can mimic the three dimensionality of the extracellular matrix of a cell. In this study, we have investigated the osteoblast response to two different chemically crosslinked (hexamethylene-1,6-diaminocarboxysulfonate (HDACS) and genipin) electrospun chitosan scaffolds and their film counterparts in order to determine how material chemistry influences cellular behavior in conjunction with material topology. In addition, material properties of each fiber scaffold such as porosity and tensile strength were considered. MLO-A5 osteoblast cells grown on chitosan-HDACS scaffolds were found to display a more organized cellular network, along with significantly more filopodia extensions, compared to those grown on chitosan-genipin scaffolds. After 2 days of growth on chitosan-HDACS fibers, a higher level of alkaline phosphatase expression in MLO-A5 cells was reported compared to that of either chitosan-genipin fibers or films. These results indicate that not only chemistry, but also surface topology is an important effecter of cellular behavior. Ultimately, chitosan-HDACS fiber scaffolds provided an adequate substrate for osteoblast attachment and proliferation.