Existing technologies have not met the challenge of designing a construct for the repair of focal cartilage defects such that it mimics the mechanical properties of and can integrate with native cartilage. Herein we describe a novel construct consisting of a non-degradable poly-vinyl alcohol (PVA) scaffold to provide long-term mechanical stability, interconnected pores to allow for the infiltration of chondrocytes, and poly-lactic glycolic acid (PLGA) microspheres for the incorporation of growth factors to enhance cellular migration. The objective of this study was to characterize the morphological features and mechanical properties of our porous PVA-PLGA construct as a function of PLGA content. Varying the PLGA content was found to have a significant effect on the morphological features of the construct. As PLGA content increased from 10% to 75%, samples exhibited a 6-fold increase in average percentage porosity, an increase in average microsphere diameter from 8 to 34 microm and an increase in average pore diameter from 29 to 111 microm. The effect of PLGA content on aggregate modulus and permeability was less profound. Our findings suggest that that morphology of the construct can be tailored to optimize cellular infiltration and the dynamic mechanical response. The experiments herein presented were conducted at the Hospital for Special Surgery.

Despite extensive research in the design of biomaterials for articular cartilage repair, there remains a need for the development of materials with the mechanical compliance to function synergistically with healthy cartilage, but porous enough to allow for tissue integration. In this study, superporous hydrogels of poly(vinyl alcohol) and poly(vinyl pyrrolidone) were prepared using a novel technique consisting of a double emulsion process. The hydrogel emulsions were physically cross-linked by freeze-thaw cycling. The hydrogels had a high degree of porosity, determined using environmental scanning electron microscopy, a technique superior to any method that involves dehydrating the samples. Increasing the volume of organic solvent increased porosity, due to cross-linking of the hydrogel solution around the droplets in the emulsion, leaving pores where the organic solvent was present. Poly(lactic-co-glyclic acid) microparticles formed and were embedded in the matrix. The mechanical properties, measured in confined creep and in unconfined, uniaxial compression, were similar to native articular cartilage. The permeability of the samples was unaffected by changing solvent content, despite changes in porosity. These materials are good candidates for tissue engineering of cartilage because they can mimic mature cartilage mechanically while providing a porous matrix through which cells can migrate and proliferate.