Fast-setting calcium phosphate scaffolds with tailored macropore formation rates for bone regeneration

Calcium phosphate cement (CPC) is highly promising for craniofacial and orthopedic repair because of its ability to self‐harden in situ to form hydroxyapatite with excellent osteoconductivity. However, its low strength, long hardening time, and lack of macroporosity limit its use. This study aimed to develop fast‐setting and antiwashout CPC scaffolds with high strength and tailored macropore formation rates. Chitosan, sodium phosphate, and hydroxypropyl methylcellulose (HPMC) were used to render CPC fast‐setting and resistant to washout. Absorbable fibers and mannitol porogen were incorporated into CPC for strength and macropores for bone ingrowth. Flexural strength, work‐of‐fracture, and elastic modulus were measured vs. immersion time in a physiological solution. Hardening time (mean ± SD; n = 6) was 69.5 ± 2.1 min for CPC‐control, 9.3 ± 2.8 min for CPC‐HPMC‐mannitol, 8.2 ± 1.5 min for CPC‐chitosan‐mannitol, and 6.7 ± 1.6 min for CPC‐chitosan‐mannitol‐fiber. The latter three compositions were resistant to washout, whereas the CPC‐control paste showed washout in a physiological solution. Immersion for 1 day dissolved mannitol and created macropores in CPC. CPC‐chitosan‐mannitol‐fiber scaffold had a strength of 4.6 ± 1.4 MPa, significantly higher than 1.2 ± 0.1 MPa of CPC‐chitosan‐mannitol scaffold and 0.3 ± 0.2 MPa of CPC‐HPMC‐mannitol scaffold (Tukey's). The strength of CPC‐chitosan‐mannitol‐fiber scaffold was maintained up to 42 days and then decreased because of fiber degradation. Work‐of‐fracture and elastic modulus showed similar trends. Long cylindrical macropore channels were formed in CPC after fiber dissolution. The resorbable, fast‐setting, anti‐washout and strong CPC scaffold should be useful in craniofacial and orthopedic repairs. The novel method of combining fast‐ and slow‐dissolution porogens/fibers to produce scaffolds with high strength and tailored macropore formation rates to match bone healing rates may have wide applicability to other biomaterials. © 2004 Wiley Periodicals, Inc. J Biomed Mater Res 68A: 725–734, 2004