Scaffolds for use in tissue engineering and method for preparing scaffolds

A method for preparing a scaffold for tissue engineering,

• the scaffold comprising n layers extending in an x-y-plane, where n is an integer≥4, each layer having a height (H) in a z-direction, and each layer comprising m volume-building components aligned in r rows in the x-y-plane, where m is an integer≥2, where r is an integer≥2;
• the method comprising:
• (A) providing a scaffold material;
• (B) preparing a scaffold from the scaffold material in an apparatus configured for additive manufacturing comprising a material source configured to deposit volume-building components of scaffold material, comprising:
• (a) forming a first layer of the scaffold on top of a base plate of the apparatus configured for additive manufacturing, comprising:
• i. depositing a first volume-building component of the scaffold material at a position on top of the base plate;
• ii. moving the material source:
• a. distance (Dysr) in the y-direction, then a distance (Dx) in the x-direction and a distance (Dyar) in the y-direction, or
• b. a distance (Dx) in the x-direction, or
• c. a distance (Dx) in the x-direction and a distance (Dyar) in the y direction;
• iii. depositing a subsequent volume-building component of the scaffold material at a subsequent position on the base plate, wherein the subsequent position is located:
• a. at a distance (Dysr) in the y-direction from the position of the preceding volume-building component deposited, and wherein the subsequent volume-building component is aligned in the x-y-plane with the preceding volume-building component deposited, then at a distance (Dx) in the x-direction and a distance (Dyar) in the y-direction, and wherein the subsequent volume-building component is aligned in the x-y-plane with the preceding volume-building component deposited, or
• b. at a distance (Dx) in the x-direction from the position of the preceding volume-building component deposited, and wherein the subsequent volume-building component is aligned in the x-y-plane with the preceding volume-building component deposited, or
• c. at a distance (Dx) in the x-direction and at a distance (Dyar) in they-direction from the position of the preceding volume-building component deposited, and wherein the subsequent volume-building component is aligned in the x-y-plane with the preceding volume-building component deposited;
• iv. repeating steps ii-iii (m−2) times;
• (b) forming (n−1) subsequent layers on top of the first layer of the scaffold in the apparatus configured for additive manufacturing, comprising:
• i. moving the material source a distance (Dh) in the z-direction, equal to the height (H) of a layer;
• ii. depositing a first volume-building component of the scaffold material at a position on top of the preceding layer, optionally at an angle (α) in the x-y-plane relative to the position of the first volume-building component of the preceding layer;
• iii. moving the material source:
• a. a distance (Dysr) in the y-direction then a distance (Dx) in the x-direction and a distance (Dyar) in the y-direction, or
• b. a distance (Dx) in the x-direction, or
• c. a distance (Dx) in the x-direction and a distance (Dyar) in the y direction;
• iv. depositing a subsequent volume-building component of the scaffold material at a subsequent position on top of the preceding layer, wherein the subsequent position is located:
• a. at a distance (Dysr) in the y-direction, from the position of the preceding volume-building component deposited, and wherein the subsequent volume-building component is aligned in the x-y-plane with the preceding volume-building component deposited, a distance (Dx) in the x-direction, and a distance (Dyar) in the y-direction, and wherein the subsequent volume-building component is aligned in the x-y-plane with the preceding volume-building component deposited, or
• b. at a distance (Dx) in the x-direction from the position of the preceding volume-building component deposited, and wherein the subsequent volume-building component is aligned in the x-y-plane with the preceding volume-building component deposited, and wherein the subsequent volume-building component is aligned in the x-y-plane with the preceding volume-building component deposited, or
• c. at a distance (Dx) in the x-direction and at a distance (Dyar) in the y-direction from the position of the preceding volume-building component deposited, and wherein the subsequent volume-building component is aligned in the x-y-plane with the preceding volume-building component deposited;
• v. repeating steps iii-iv (m−2) times;
• vi. repeating steps i-v (n−2) times;
• provided that the distance (Dx) in one or more layers is different from the distance (Dx) of the preceding one or more of layers;
• provided that the m volume-building components of one or more layers are distributed at an angle (α) in the x-y-plane relative to the m volume-building components of any adjacent one or more layers;
• thereby preparing a scaffold comprising a gradient distribution of volume-building components in the z-direction of the scaffold, and a staggered distribution of volume-building components in the x-y-plane of the scaffold;
• wherein the height (H), the distance (Dx), the distance (Dysr), the distance (Dyar) and the angle (α) together define a size and shape of pores in the scaffold.