Single-Step Fabrication of Chitosan-Containing 3D Nanofiber Scaffold for Bone Tissue Engineering

Considering the increasing aging population and the exponential rise in bone regeneration and graft usage operations due to trauma and degeneration, the annual cost of such procedures was projected to reach $1 billion by 2015. Bone tissue engineering offers an innovative alternative to traditional bone grafting by promoting cell migration and supporting vascularization, emphasizing the importance of mimicking the natural properties of transplanted tissue. This approach represents a groundbreaking solution in the field of bone transplantation. In this study, compressible and easily shapeable three-dimensional composite fibrous materials were developed for the treatment of bone defects with irregular geometries. These materials were specifically designed to be suitable for use in addressing complex and irregular bone damage. To achieve this, scaffolds based on polycaprolactone (PCL), a polyester approved by the U.S. Food and Drug Administration (FDA); chitosan (CS), a polysaccharide; gelatin (GEL), a protein; and varying ratios of nano-hydroxyapatite (nHA) were produced and optimized using the electrospinning method. This study focused on optimizing the PCL/GEL/CS/nHA composite materials to achieve a three-dimensional, cotton-like structure with high porosity. Scanning Electron Microscopy (SEM) analyses confirmed the successful formation of three-dimensional nanofiber architectures with enhanced porosity and an interconnected network structure. The cotton-like, compressible, and moldable architecture, achieved through a specially designed spherical collector in a single-step process, makes these scaffolds exceptionally well-suited for filling complex and irregularly shaped bone defects. Water vapor transmission rate (WVTR), swelling behavior, and biodegradation tests demonstrated that the developed scaffolds possess suitable moisture permeability, water absorption capacity, and a controlled degradation profile. These results indicate that the produced three-dimensional PCL/GEL/CS/nHA scaffolds have strong potential for application in bone tissue engineering.