Structural and topological design of conformal bilayered scaffolds for bone tissue engineering

A fundamental outcome of bone tissue engineering is the regeneration of bone defects presenting large dimensions. A promising solution in biomedical practice is the implantation of biomimetic scaffolds, i.e. porous structures mimicking the natural shapes of healthy bone tissues, which are colonized by mesenchymal stem cells and that support the growth of the regenerating tissues, until the complete healing process is realized. This work presented a workflow for the geometrical modeling and the mechanical design of beam-based, bilayered, and conformal scaffolds, mimicking the human cortico-cancellous bone structure for filling a large dimension defect in the mandibular bone of an injured patient. An isotropic Voronoi topology built on a refined point set generated by a high-quality meshing algorithm was adopted for lattice generation, which led to an open-cell architecture characterized by full connectivity and uniform cell size. Such geometrical and structural features represent crucially important requirements for maximizing the osteointegration and the vascularization of the implanted scaffold. An irregular scaffold was modelled, including a cortical and a sponge layer. The beam radii of both layers were determined by matching the elastic properties of the corresponding bone tissues, thus minimizing the stress shielding effects. Interestingly, several scaffold properties deriving from the proposed procedure, such as the porosity and the pore size, were in good agreement with those reported in the literature.