Combination of fused deposition modeling and gas foaming technique to fabricated hierarchical macro/microporous polymer scaffolds

•Hierarchical macro/microporous polymer scaffold was fabricated.•Scaffolds with 100–800 μm macropores were initially fabricated by using FDM technique.•Scaffolds with 1–10 μm micropores were then fabricated by using gas foaming.•The integrated manufacturing method can fabricate grotesque and large scaffolds for bone tissue engineering application.

The design and fabrication of porous scaffold remains a major challenge in bone tissue engineering. Hierarchical microporous and macroporous structures in scaffold contribute different biological functions to tissue regeneration. This study introduced an integrated manufacturing method to fabricate hierarchical porous polymer scaffolds. Firstly, polylactic acid (PLA) scaffolds with 100–800 μm macropores were fabricated by applying fused deposition modeling (FDM) techniques. Then, 1–10 μm micropores were generated in scaffolds through gas foaming. This combined technique avoids the disadvantages of pure 3DP or gas foaming technology and elicits positive cooperative effects to fabricate hierarchical porous scaffolds. The design of porosity in scaffold could offer innovative opportunities to control cell performance within 3D microenvironments.

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