Vacuum forming of thermoplastic bioabsorbable scaffolds for use in auricular reconstruction

A method of forming an auricular scaffold comprising:

• providing a mold comprising a shape and a size representing an auricular cartilage;
• heating a biocompatible polymer sheet to a first temperature, wherein the biocompatible polymer sheet comprises a plurality of holes from about 0.5 mm to about 2.0 mm in diameter prior to heating, and wherein the holes extend through the biocompatible polymer sheet;
• contacting the biocompatible polymer sheet that was heated to the mold;
• applying a vacuum to the biocompatible polymer sheet that was heated to draw the biocompatible polymer sheet over the mold;
• cooling the biocompatible polymer sheet, that was drawn over the mold, below the first temperature to fix the shape representing the auricular cartilage in the biocompatible polymer sheet,
• removing the biocompatible polymer sheet that was drawn over the mold and cooled from the mold;
• and
• trimming excess biocompatible polymer sheet to form the auricular scaffold, wherein the plurality of holes are positioned to facilitate one or more of packing, retention, and structural stability of crushed cartilage packed within the auricular scaffold.