Fabrication of alumina porous scaffolds with aligned oriented pores for bone tissue engineering applications

In the present study, porous alumina scaffolds with specific orientation and anisotropic properties are fabricated for application in bone tissue repair. The scaffolds with double shape pores, tubular oriented and isotropic rounded pores, were prepared using alumina and silica as starting materials by the slip casting route. Milled polyurethane foam and silk fibers were applied as replica materials as well. The effect of fiber types and diameter and number of fibers on the microstructure and pore size was studied. Moreover, different characteristics such as porosity, density, orientation, flexural strength and compressive strength of the samples were investigated. Results showed that various fibers with different diameters and numbers led to forming the pores with different pore sizes, microstructure and consequently changes in the physical and mechanical properties. In addition, the simultaneous presence of fibers and particles led to more porous scaffolds. The oriented tiny micro-tube and rounded pores were observed in all porous ceramic scaffolds. Mechanical testing showed an anisotropy in the mechanical behaviors such that higher strengths were observed in the oriented pore direction than that of transverse. With increasing the number and diameter of silk fibers, the scaffolds with a high porosity up to 68 vol% and proper flexural strength were obtained.