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Design, Fabrication, and Evaluation of Hybrid Polycaprolactone/Graphene Scaffold Based on Additive Manufacturing and Electrospinning
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Design, Fabrication, and Evaluation of Hybrid Polycaprolactone/Graphene Scaffold Based on Additive Manufacturing and Electrospinning
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Design, Fabrication, and Evaluation of Hybrid Polycaprolactone/Graphene Scaffold Based on Additive Manufacturing and Electrospinning
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Journal Article
Design, Fabrication, and Evaluation of Hybrid Polycaprolactone/Graphene Scaffold Based on Additive Manufacturing and Electrospinning
2025
Overview
Electrospinning and additive manufacturing (AM) are key technologies for fabricating bone tissue engineering scaffolds, each with unique strengths and limitations. Electrospinning produces nanoscale fibers that promote cell attachment and affinity on 2D surfaces but offer limited mechanical strength. In contrast, AM creates 3D scaffolds with enhanced mechanical properties through precise control of topological structures, but the capability to stimulate and guide cell growth is limited compared to electrospun nanoscale fibers. Combining both methods holds potential for next‐generation scaffold development with desirable mechanical and biological properties. This study investigates the fabrication of multi‐scale and multi‐material scaffolds by integrating extrusion‐based AM and solution electrospinning. Polycaprolactone (PCL), a biocompatible and biodegradable polymer, served as the base material, while graphene nanosheets were incorporated as functional fillers to enhance mechanical, electrical, surface, and biological properties. Solution electrospinning was first optimized, and hybrid scaffolds were fabricated, with an image‐based optimization method, obtaining 87% of the fibres well‐aligned with the designed direction. Optimal scaffold composition (PCL nanofibers with 1 wt.% graphene + PCL microfibers with 3 wt.% graphene) was also identified based on 2D mesh characterization results (186% enhancement of the mechanical property and 23% enhancement of the cell proliferation result, compared with neat PCL). The findings demonstrate the potential of this hybrid fabrication approach for developing advanced polymer‐carbon nanomaterial scaffolds for bone tissue regeneration applications. A multi‐scale and multi‐material PCL/graphene scaffold was successfully fabricated by integrating extrusion‐based AM and solution electrospinning. The process was optimized using an image‐based method, achieving 87% fiber alignment with the intended orientation. The combination of 3D printed nanofibers (1 wt.% graphene) and electrospun microfibers (3 wt.% graphene) was identified as optimal, based on comprehensive 2D mesh characterization.
