The effect of 3D-printed bone tissue scaffolds geometrical designs on bacterial biofilm formation

Bone fractures are recognized as a global health problem. A common strategy to tackle this issue is to employ a tissue engineering scaffold to accelerate tissue healing. However, one of the main challenges that can result in delaying the recovery is the risk of bacterial infections. This study aims to assess the impact of the geometry and the porosity of tissue scaffolds on the Staphylococcus aureus biofilm formation. Three triply periodic minimal surface designs of Schwarz primitive (SP), gyroid (GY), and Schwarz diamond (SD) and re-entrant auxetic (RE) design were examined and compared to a reference design (RD) considering two different porosity levels of 75% and 45%. The amount of biofilm was quantified using crystal violet assay and was visualized using scanning electron microscopy. The SP scaffold, with low porosity, exhibited a significantly less amount of bacterial biofilm formation and was regarded as having the best design among the others, while the SD with low porosity showed the greatest amount of biofilm. The morphological analysis was also in line with the crystal violet assay results. On the other hand, the surface roughness was affected by the complexity, geometrical variations, and limitations of fused filament fabrication three-dimensional printing. For the RD, SP, GY, and SD designs, an increase in surface roughness was demonstrated to increase the production of bacterial biofilms. Without statistical significance, the RE design showed the opposite trend. Contrary to other designs, the increase in pore size of the SP and GY designs was associated with the development of bacterial biofilms. This study suggests that it is possible to minimize the likelihood of bacterial biofilm formation by optimizing the scaffold geometry and its manufacturing.