Tuning Mechanical Performance of PCL Scaffolds: Influence of 3D Bioprinting Parameters, Polymer Concentration, and Solvent Selection

Abstract

The mechanical performance of three-dimensional (3D) bioprinted scaffolds is susceptible to printing parameters and material formulation. In this study, poly (epsilon-caprolactone) (PCL) scaffolds were fabricated using four different polymer concentrations (10%, 25%, 50%, and 75% w/v) to investigate how these variations, along with process parameters, influence mechanical behavior. Maintaining the structural integrity of bioprinted constructs requires careful optimization of polymer concentration and precise control over parameters such as printing speed, pressure, and infill density. Tensile tests were conducted to evaluate the effects of these variables. Among the tested conditions, a 50% (w/v) concentration allowed for a broader operational window, enabling fabrication across a range of printing speeds and pressures. At a printing speed of 5 mm s-1, PCL-DCM exhibited a Young's modulus of 39.0 MPa, while PCL-CF samples printed at 10 mm s-1 achieved the highest modulus of 32.0 MPa. Notably, when the printing speed was kept constant, applying higher pressures led to an increase in Young's modulus, suggesting that pressure plays a key role in enhancing scaffold stiffness. When comparing the 50% and 75% (w/v) polymer concentrations, the 50% (w/v) formulation stood out by offering both higher elongation and greater stiffness, which makes it particularly suitable for load-bearing applications. These findings provide a quantitative framework for optimizing extrusion-based bioprinting of PCL scaffolds, with implications for customized biomedical implants and regenerative medicine.