Background: In this study, three-dimensional (3D)-printed polycaprolactone (PCL) scaffolds were fabricated using the fused deposition modeling (FDM) technique with different geometric patterns and underwent finite element analysis under tensile, compressive, and bending loadings, along with experimental testing.
Methods: The 3D models of six scaffolds were designed in SolidWorks software. Scaffolds No. 1, 2, 3, 5, and 6 had a disk geometry with a diameter of 4 cm, while scaffold No. 4 was square-shaped with a side length of 3 cm. Their cross-sectional thickness and overall height were kept constant; differences pertained exclusively to pore geometry and pore arrangement. They underwent numerical study using von Mises stress, displacements (URES), and equivalent strain (ESTRN) maps, and were validated against experimental results. The surface morphology and fracture characteristics were examined using scanning electron microscopy (SEM) images.
Results: Scaffold No. 5 was the most efficient model and was selected as the optimal pattern. The SEM image of this optimal scaffold confirmed the geometric regularity of the cylindrical pore arrangement and the characteristic layer-by-layer filament deposition of the FDM process, while post-tensile fracture SEM imaging revealed interlayer separation and polymer features consistent with the ductile nature of PCLs. The optimal scaffold with straight cylindrical pores provided lower displacement and more uniform stress/strain distribution compared to the one with conical pores, while the addition of a symmetric protrusion on the opposite face of the scaffold did not yield a significant mechanical benefit.
Conclusion: The findings underscore the decisive role of geometry and pore configuration in tuning the mechanical microenvironment of PCL scaffolds for tissue engineering applications.