Nerve repair scaffolds having high microchannel volume and methods for making the same

A tissue scaffold for neural tissue growth comprising:

• a porous sheath having a first length and comprising a first plurality of pores having an average pore size of greater than or equal to about 10 μm to less than or equal to about 50 μm;
• and
• a plurality of microchannels disposed within the sheath defining a second length, wherein each microchannel of the plurality comprises (i) a biocompatible and biodegradable material comprising a polyester polymer, and (ii) a porous wall comprising a second plurality of pores having an average pore size of greater than or equal to about 10 μm to less than or equal to about 50 μm, wherein the porous wall has a thickness of greater than or equal to about 10 μm to less than or equal to about 100 μm and is free of line-of-sight porosity to prevent or minimize cellular growth through the porous wall, wherein the first length is greater than the second length and the tissue scaffold has an open volume of greater than or equal to about 60 volume %.

A tissue scaffold for neural tissue growth comprising:

• a porous sheath;
• and
• a plurality of microchannels disposed within and closely packed in the porous sheath, so that a portion of each microchannel contacts another microchannel of the plurality and each microchannel of the plurality comprises (i) a biocompatible and biodegradable material comprising a polyester polymer, and (ii) a porous wall comprising a plurality of pores having an average pore size of greater than or equal to about 10 μm to less than or equal to about 50 μm, wherein the porous wall has a thickness of greater than or equal to about 10 μm to less than or equal to about 100 μm and is free of line-of-sight porosity to prevent or minimize cellular growth through the porous wall, wherein the tissue scaffold has an open volume of greater than or equal to about 60 volume %.