3D printed cell-free bilayer porous scaffold based on alginate with biomimetic microenvironment for osteochondral defect repair

Despite significant progress in repairing osteochondral injuries using 3D printing technology, most cartilage layer scaffolds are made of degradable materials, making it difficult to simultaneously provide extracellular matrix functionality while replicating the mechanical properties of natural cartilage layers. Additionally, their degradation rate is challenging to align with cartilage regeneration. Furthermore, double-layer scaffolds commonly used for repairing osteochondral often exhibit inadequate bonding between the cartilage layer scaffolds and bone layer scaffolds. To solve these problems, we presented a bilayer scaffold composed of a 3D printed non-degradable thermoplastic polyurethane (TPU) scaffold filled with hydrogel (Gel) made of gelatin and sodium alginate as the cartilage layer (noted as TPU/Gel), meanwhile, a 3D printed polylactic acid (PLA) scaffold containing 10 % hydroxyapatite (HA) as the bone layer (noted as PLA/HA). At the junction of the bone layer and cartilage layer, TPU tightly bonded with the bone layer scaffold under high temperatures. The hydrogel filling within the TPU layer of cartilage served not only to lubricate the joint surface but also aided in creating a 3D microenvironment. The non-degradable nature of TPU allowed the cartilage layer scaffold to seamlessly integrate with the surrounding regenerated cartilage, achieving permanent replacement and providing shock absorption and weight-bearing effects. This effectively addressed the mechanical challenges associated with cartilage regeneration and resolved the inconsistency between cartilage regeneration and material degradation rates.