Devices and Methods for Tissue Engineering

Abstract

A tissue scaffold fabricated from bioinert fiber forms a rigid three-dimensional porous matrix having a bioinert composition. Porosity in the form of interconnected pore space is provided by the space between the bioinert fiber in the porous matrix. Strength of the porous matrix is provided by bioinert fiber fused and bonded into the rigid three-dimensional matrix having a specific pore size and pore size distribution. The tissue scaffold supports tissue in-growth to provide osteoconductivity as a tissue scaffold, used for the repair of damaged and/or diseased bone tissue.

1 . A method of fabricating a porous tissue scaffold comprising:
 creating a homogeneous mixture of non-volatile components consisting essentially of fiber, and volatile components consisting essentially of a binder and a pore former wherein the volatile components amount to greater than 50% of the homogeneous mixture;   forming the homogeneous mixture into a shaped object;   heating the shaped object in a first furnace heating process to remove the volatile components; and   heating the shaped object in a second furnace heating process to form bonds between the fibers to form a rigid, porous structure.   
     
     
         2 . The method according to  claim 1  wherein the fiber is composed of titanium. 
     
     
         3 . The method according to  claim 1  wherein the fiber is composed of tantalum. 
     
     
         4 . The method according to  claim 1  wherein the fiber has a diameter ranging from about 2 microns to about 500 microns. 
     
     
         5 . The method according to  claim 4  wherein the fiber has a diameter ranging from about 25 microns to about 200 microns. 
     
     
         6 . The method according to  claim 1  wherein the fiber is cut to a length of about 3 to about 1000 times the diameter of the fiber. 
     
     
         7 . The method according to  claim 1  wherein the first furnace heating process is performed in a nitrogen-purged furnace. 
     
     
         8 . The method according to  claim 1  wherein the second furnace heating process is performed in a vacuum furnace. 
     
     
         9 . The method according to  claim 1  wherein the first furnace heating process is performed with a heating rate of less than 2° C./minute. 
     
     
         10 . The method according to  claim 9  wherein the first furnace heating process is performed with a heating rate between 0.5° C./minute and 0.7° C./minute. 
     
     
         11 . A method of fabricating a porous tissue scaffold comprising:
 creating a homogeneous mixture of non-volatile components consisting of fiber and a bonding agent, and volatile components consisting essentially of a binder and a pore former;   forming the homogeneous mixture into a shaped object;   heating the shaped object in a first furnace heating process to remove the volatile components; and   heating the shaped object in a second furnace heating process to form bonds between the fibers using the bonding agent to form a rigid, porous structure.   
     
     
         12 . The method according to  claim 11  wherein the fiber is composed of titanium. 
     
     
         13 . The method according to  claim 11  wherein the fiber is composed of tantalum. 
     
     
         14 . The method according to  claim 11  wherein the fiber has a diameter ranging from about 2 microns to about 500 microns. 
     
     
         15 . The method according to  claim 14  wherein the fiber has a diameter ranging from about 25 microns to about 200 microns. 
     
     
         16 . The method according to  claim 11  wherein the fiber is cut to a length of about 3 to about 1000 times the diameter of the fiber. 
     
     
         17 . The method according to  claim 11  wherein the first furnace heating process is performed in a nitrogen-purged furnace. 
     
     
         18 . The method according to  claim 11  wherein the second furnace heating process is performed in a vacuum furnace. 
     
     
         19 . The method according to  claim 11  wherein the first furnace heating process is performed with a heating rate of less than 2° C./minute. 
     
     
         20 . The method according to  claim 19  wherein the first furnace heating process is performed with a heating rate between 0.5° C./minute and 0.7° C./minute.