Controlled Mechanical Property Gradients Within a Digital Light Processing Printed Hydrogel-Composite Osteochondral Scaffold

Kevin N Eckstein; John E Hergert; Asais Camila Uzcategui; Sarah A Schoonraad; Stephanie J Bryant; Robert R McLeod; Virginia L Ferguson

doi:10.1007/s10439-024-03516-x

Controlled Mechanical Property Gradients Within a Digital Light Processing Printed Hydrogel-Composite Osteochondral Scaffold

Ann Biomed Eng. 2024 Apr 29. doi: 10.1007/s10439-024-03516-x. Online ahead of print.

Authors

Kevin N Eckstein¹, John E Hergert², Asais Camila Uzcategui², Sarah A Schoonraad³, Stephanie J Bryant^{2

4

3}, Robert R McLeod^{2

5}, Virginia L Ferguson^{6

7

8}

Affiliations

¹ Paul M. Rady Department of Mechanical Engineering, University of Colorado at Boulder, 427 UCB, Boulder, CO, 80309, USA.
² Materials Science and Engineering Program, University of Colorado at Boulder, Boulder, CO, USA.
³ Department of Chemical and Biological Engineering, University of Colorado at Boulder, Boulder, CO, USA.
⁴ BioFrontiers Institute, University of Colorado at Boulder, Boulder, CO, USA.
⁵ Department of Electrical, Computer & Energy Engineering, University of Colorado at Boulder, Boulder, CO, USA.
⁶ Paul M. Rady Department of Mechanical Engineering, University of Colorado at Boulder, 427 UCB, Boulder, CO, 80309, USA. virginia.ferguson@colorado.edu.
⁷ Materials Science and Engineering Program, University of Colorado at Boulder, Boulder, CO, USA. virginia.ferguson@colorado.edu.
⁸ BioFrontiers Institute, University of Colorado at Boulder, Boulder, CO, USA. virginia.ferguson@colorado.edu.

PMID: 38684606
DOI: 10.1007/s10439-024-03516-x

Abstract

Tissue engineered scaffolds are needed to support physiological loads and emulate the micrometer-scale strain gradients within tissues that guide cell mechanobiological responses. We designed and fabricated micro-truss structures to possess spatially varying geometry and controlled stiffness gradients. Using a custom projection microstereolithography (μSLA) system, using digital light projection (DLP), and photopolymerizable poly(ethylene glycol) diacrylate (PEGDA) hydrogel monomers, three designs with feature sizes < 200 μm were formed: (1) uniform structure with 1 MPa structural modulus ( $E$ ) designed to match equilibrium modulus of healthy articular cartilage, (2) $E$ = 1 MPa gradient structure designed to vary strain with depth, and (3) osteochondral bilayer with distinct cartilage ( $E$ = 1 MPa) and bone ( $E$ = 7 MPa) layers. Finite element models (FEM) guided design and predicted the local mechanical environment. Empty trusses and poly(ethylene glycol) norbornene hydrogel-infilled composite trusses were compressed during X-ray microscopy (XRM) imaging to evaluate regional stiffnesses. Our designs achieved target moduli for cartilage and bone while maintaining 68-81% porosity. Combined XRM imaging and compression of empty and hydrogel-infilled micro-truss structures revealed regional stiffnesses that were accurately predicted by FEM. In the infilling hydrogel, FEM demonstrated the stress-shielding effect of reinforcing structures while predicting strain distributions. Composite scaffolds made from stiff μSLA-printed polymers support physiological load levels and enable controlled mechanical property gradients which may improve in vivo outcomes for osteochondral defect tissue regeneration. Advanced 3D imaging and FE analysis provide insights into the local mechanical environment surrounding cells in composite scaffolds.

Keywords: 3D printing; Cartilage; Composite; Mechanical properties; Osteochondral; Scaffold.

Abstract

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