Evaporation-induced self-assembly of hierarchical zinc silicate hybrid scaffolds for bone tissue engineering: Meso and macro scale porosity design

In this study, zinc silicate hybrid scaffolds with hierarchical meso/macroporous structures were synthesized using evaporation-induced self-assembly and sacrificial foamy templates. F127 triblock copolymer and polyurethane (PU) foam served as templates for mesoporosity and macroporosity, respectively. The scaffolds were calcined at 550, 650, and 750 °C for 2 h to remove the templates and form the crystalline phase. Analytical techniques, including BET, XRD, SEM, FTIR, and STA, were used to study the impact of calcination temperature on the scaffolds' meso-texture and crystalline phase. Results showed that increasing the calcination temperature to 750 °C significantly enhanced the overall crystallinity. The crystallized ZnO content increased from 10.3 wt% to 32 wt%, and the willemite (Zn₂SiO₄) crystalline phase formed. Willemite content was approximately 3 wt% at 650 °C and 67 wt% at 750 °C, as determined by quantitative XRD analyses via Rietveld refinement. The emergence of the willemite phase adversely impacted the specific surface area, leading to a reduction from 123.18 m²/g to 2.18 m²/g, and compromised meso-texture-related characteristics, indicating a substantial disruption in mesoporosity. The pure willemite sample was also obtained by increasing the calcination temperature up to 1000 °C. Although the sample contained no secondary phase, the specific surface area and total mesopore volume were drastically reduced, indicating the negative effect of high calcination temperature on mesoporosity. In contrast to the mesostructure, the macrostructure of the scaffolds exhibited negligible sensitivity to calcination temperature, maintaining a mean macropore diameter of around 200 μm. Furthermore, the in vitro performance of the scaffolds was evaluated by assessing apatite formation ability, degradability, and cytocompatibility. It was demonstrated that the scaffolds calcined at 750 °C exhibited superior performance in terms of apatite formation and cytocompatibility when cultivated with MG-63 human osteosarcoma cells.