Template-assisted electrohydrodynamic atomization of polycaprolactone for orthopedic patterning applications

• For the first time, hexagonal PCL patterns have been applied onto Ti using TAEA.
• TAEA produces controlled polymer topographies at ambient temperature.
• PCL concentration (2–15 wt.%) and flow rate (1–25 μl min− 1) were systematically varied.
• Pattern hardness was 1.6 MPa and effective modulus was 12 MPa for load rate 0.1 μN/s.
• Mean pattern thickness was ~ 34 μm, increasing with flow rate and PCL concentration.

This paper presents the development of the novel deposition of biodegradable polycaprolactone (PCL) polymer patterns on a metallic substrate using a jet spraying technique, template-assisted electrohydrodynamic atomization (TAEA), at ambient temperature. The structure of patterns was controlled by systematically varying the polymer concentration (2–15 wt.%) and the flow rate (1–25 μl min− 1). Polymer deposition was carried out in the stable cone-jet mode to precisely control the surface structure and morphology. The patterns were studied by optical microscopy, scanning electron microscopy and profilometry, and a high degree of control over the pattern geometry and thickness was achieved by varying the spraying time. The hardness and the effective elastic modulus of the polymer patterns were estimated using nanoindentation. The effect of load, loading rate and the holding time on the hardness and effective elastic modulus was derived. Optimal results were obtained with 5 wt.% PCL in DMAC solution sprayed within the stable cone-jet mode operating window at a flow rate of 15 μl min− 1 for 300 s at 11.1 kV with a working distance of 60 mm. Hexagonal patterns were well-defined and repeatable with thickness of ~ 34 μm. The hardness is 1.6 MPa at a loading rate of 0.1 μN/s and nearly halved when the load rate was increased to 1 μN/s. The effective elastic modulus of ~ 12 MPa is obtained for a load rate of 0.1 μN/s.

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