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Biotechnol. Appl. Biochem.

(2004) 39, 49–58 (Printed in Great Britain) 49

Computer-aided tissue engineering: application to biomimetic


modelling and design of tissue scaffolds

Wei Sun1 , Binil Starly, Andrew Darling and Connie Gomez

Laboratory for Computer-Aided Tissue Engineering, Department of Mechanical Engineering and Mechanics,
College of Engineering, Drexel University, 3141 Chestnut Street, Philadelphia, PA 19104, U.S.A.

Computer-aided tissue engineering (CATE) enables for appropriate bone ingrowth and healing. In addition, the
many novel approaches in modelling, design and fabri- designed scaffold structure should be able to have required
cation of complex tissue substitutes with enhanced mechanical strength after implantation, particularly in the
functionality and improved cell–matrix interactions. reconstruction of hard and load-bearing tissues such as bone
Central to CATE is its bio-tissue informatics model and cartilage. The strength of biodegradable tissue scaffolds
that represents tissue biological, biomechanical and must not decline rapidly and must degrade at a rate similar to
biochemical information that serves as a central re- the growth of new tissue cells. Therefore the tissue scaffold
pository to interface design, simulation and tissue structure should be compliant, both biologically as well as
fabrication. The present paper discusses the application mechanically, at the site of implantation and should at best
of a CATE approach to the biomimetic design of bone mimic the natural bone properties in order to function as a
tissue scaffold. A general CATE-based process for true bone substitute.
biomimetic modelling, anatomic reconstruction, com- Central to CATE approach is its ability to represent
puter-assisted-design of tissue scaffold, quantitative- pertinent tissue biological, biomechanical and biochemical
computed-tomography characterization, finite ele- information as a computer-based bio-tissue informatics
ment analysis and freeform extruding deposition for model. This model can be used as an effective communi-
fabrication of scaffold is presented. cation tool between biologists and tissue engineers, with
the database of the model serving as a central repository
to interface design, simulation and manufacturing of tissue
Introduction substitutes. An overview of CATE in terms of the three
major categories, particularly in description of the meth-
Computer-aided tissue engineering (CATE) is a newly odology of using high-resolution non-invasive imaging for
emerging field that can be classified within three major CATE model generation, image-based three-dimensional
categories: (1) computer-aided tissue modelling; (2) com- (3D) reconstruction, computer-aided tissue informatics,
puter-aided tissue informatics; and (3) computer-aided tissue tissue scaffold design, freeform fabrication and bio-blueprint
scaffold design and manufacturing ([1]; our review in this modelling and its application to 3D organ printing are
issue [2]). Application of CATE allows us to explore presented in our review in this issue [2]. The objective of
many novel ideas in modelling, design and fabrication of the present paper is to discuss the application of the CATE
tissue scaffolds with enhanced functionality and improved approach for a biomimetic design of bone tissue scaffold.
interactions with cells. This is particularly useful in modelling The outline of the developed biomimetic approach with
and design of complex bone tissue scaffolds and replacement its application in modelling heterogeneous bone structure,
structures that require us to simultaneously consider quantitative computed tomography characterization of bone
many biological and biophysical design requirements [3–5]. tissue properties, and various modeling alternatives to
Generation of functional tissue or organ structure requires
a scaffold to guide the overall shape and three-dimensional
Key words: bone scaffold, computer-aided design (CAD), computer-aided
organization of multiple cell types. The internal architecture tissue engineering (CATE), tissue engineering, tissue scaffold design.
of a bone scaffold cannot be chosen at ease, and various Abbreviations used: CATE, computer-aided tissue engineering; CAD,
factors need to be considered, such as porosity, pore size computer-aided design; CT, computed tomography; FEA, fine element
analysis; IGES, initial graphics exchange specification; MRI,
and interconnectivity of the tissue scaffold structure, have magnetic-resonance imaging; PLGA, poly(DL-lactic-co-glycollic acid); PLLA,
all been identified to be important factors that make a tissue poly(L-lactic acid); QCT, quantitative computed tomography; NURBS,
scaffold successful. These factors aid in the transportation non-uniform rational B-spline; STEP, standard for exchange of product
model data; STL, stereolithography; 3D, three-dimensional.
of nutrients that would enable the growth of new cells 1
To whom correspondence should be addressed (e-mail
and allow the tissue scaffold to act as a suitable template sunwei@drexel.edu).


C 2004 Portland Press Ltd
50 W. Sun and others

construct a CAD (computer-aided design)-based tissue the QCT (qualitative computed tomography) method. The
heterogeneous model will be introduced in the section unit cells with matching properties are selected as candi-
entitled ‘CATE based biomimetic modelling of bone date unit cells to make up the tissue scaffold. The candidate
scaffolds’. The design and analysis of different tissue unit cells will be further evaluated according to their internal
representative unit cells and its utilization as building blocks architectures and the intended biological purpose. Using
to assemble the designed tissue scaffold will be presented CAD solid-modelling-based Boolean operations, a set of
in the section entitled ‘Design and characterization of bone such selected unit cells would be integrated with the shape
scaffold and tissue representative unit cells’, followed by of the bone to form the bone tissue scaffold with specified
an introduction to using an in-house developed fabrication internal architecture and structural properties to match that
planning and extruding deposition method to freeform fabri- of the actual replaced bone based on the characterization
cate the tissue scaffold in the section entitled ‘Freeform analysis. Once the complete CAD database of the bone
fabrication of tissue scaffold’ and a summary, discussion and tissue scaffold structure is in place, process planning and
conclusions in the final section (‘Conclusions’). toolpath instructions will be generated based on solid-
freeform-fabrications techniques, which would be able to
manufacture the designed tissue structures. The overall
procedure for the CATE-based biomimetic modelling and
CATE-based biomimetic modelling design of the bone tissue scaffold is illustrated in Figure 1
of bone scaffolds and further described in the following steps.

Bone tissue scaffolds need to have certain characteristics of


Step 1: image acquisition
their own in order to function as a true bone substitute
Our region of study involved the CT (computed tomo-
that satisfies the biological, mechanical and geometrical
graphy) images obtained from that of a proximal femur bone.
constraints. Such characteristics include: (1) biological
In all, 34 sliced images were obtained each, of 2 mm slices,
requirements – the designed scaffold must facilitate cell
thereby totalling a length of 68 mm of the proximal femur
attachment and distribution, growth of regenerative tissue
bone. These sliced images were loaded into MIMICS and
and facilitate the transport of nutrients and signals. This
organized in a sequential manner and oriented for its top,
requirement can be achieved by controlling the porosity
bottom, anterior and posterior positions.
of the structure, by providing appropriate interconnectivity
inside the structure, and by selecting suitable biocompatible
materials; (2) mechanical requirement – the designed scaf- Step 2: segmentation and characterization process
fold must provide structural support at the site of replace- Once loaded, the region of interest was identified and a 3D
ment while the tissue regenerates to occupy the space voxel model of the bone under study had to be made. As
defined by the scaffold structure. Scaffold structures need a first step, an appropriate threshold range was found that
to be defined to possess the required mechanical stiffness could best capture the relevant information contained in
and strength of the replaced structure; and (3) anatomical the femur. Using this threshold value, all pixels within this
requirement – it must be of an appropriate geometric size range were grown to a colour mask and hence the segmen-
that fits in at the site of replacement [6–8]. tation process achieved by making use of region-growing
Our overall CATE design approach begins with the techniques available in the software. The segmentation was
acquisition of non-invasive images and image processing achieved using two different approaches, each approach
of appropriate tissue region of interest. This is followed serving a particular purpose. In the first approach, the
by a 3D reconstruction of anatomical structure using whole proximal femur structure was grown into one
commercially available medical reconstructive and reverse single colour mask representing one single threshold range.
engineering software (MIMICS [9] and Geomagic [10]). With this approach, the average threshold value for the
The next step is to appropriately devise a process by whole structure could be obtained. This average threshold
which tissue structural heterogeneity can be characterized value was in turn correlated to the quantitative computed
through a homogenization technique, and to define tissue tomography number (QCT#) represented in Hounsfield
anatomic representative features for generating CAD units (HU) by using a simple relation as follows:
(Pro/ENGINEER C
[11])-based unit cells. On the basis of the
QCT# = threshold value − 1024 (1)
designed CAD geometrical configuration and the intended
scaffolding materials, a finite element method (ABAQUS In the second approach, described as the homogenization
[12]) is applied to determine the corresponding mechanical technique, the femur structure was divided into layers and
properties. Those properties are further compared with then an average QCT# for each layer found. A collection
the replaced-tissue mechanical properties characterized by of slices of the femur was grouped as layers and segmented

C 2004 Portland Press Ltd
Computer-aided tissue engineering: application to biomimetic modelling and design of tissue scaffolds 51

Figure 1 Overall procedures of modelling and design of biomimetic bone scaffold

using relations available in published literature. This density


can in turn be then related to elasticity (E), allowing the
heterogeneous elasticity of the bone to be defined through
the relations obtained as described in [13,14]:

For QCT < 816 : ρ = 1.9 × 10−3 · QCT + 0.105 and


E = 0.06 + 0.9 · ρ 2 (2)
For QCT < 816 : ρ = 7.69 × 10 + 1.028 and −4

E = 0.09 · ρ 7.4 (3)


Figure 2 Average QCT values measured from CT
The structural heterogeneity of the bone can thus be
defined through the associated bone Young’s modulus. The
characterization results are as shown in Table 1. The last
row in the Table indicates the QCT# retrieved when a
using different colour masks. Each layer thickness was single colour mask was considered. The calculated E is in
about 10 mm and there were about seven layers in all. accordance with published data for cancellous bone, namely
An average QCT# was obtained for each layer in order to 0.5–1.5 GPa. It is noteworthy that both cancellous and
characterize the tissue heterogeneity (Figure 2). The QCT# cortical bone have been considered smeared together as
retrieved from the appropriate layers is then correlated one structure in each layer and hence the slightly higher
with the density (ρ) of the bone by a linear interpolation values obtained by this technique.

C 2004 Portland Press Ltd
52 W. Sun and others

Table 1 Bone spatial heterogeneity: seven-layer model tissue model using three different interfaces with CT/MRI
Layer no. QCT# 2
Density (g/cm ) E (MPa)
(magnetic-resonance imaging) data: (1) MedCAD interface
(direct interface with medical-imaging data within MIMICS
1 728 1.4882 2053 [9]); (2) reverse-engineering interface (reconstruction from
2 603 1.2507 1467
3 479 1.0151 987 point to curve to surface to solid using Geomagic [11]);
4 385 0.8365 690 and (3) STL (stereolithography) interface (using STL from
5 374 0.8156 658 MIMICS). The process flow chart of the three approaches is
6 390 0.8460 704
7 359 0.7871 617 presented in Figure 3.
Entire bone 474 1.0056 970
Process path 1: MedCAD interface This interface bridges the
gap between medical imaging and CAD design software,
meaning that this interface can export data from the imaging
Step 3: CAD model generation system to the CAD system and vice versa. The IGES (initial
Once the bone structure has been characterized, a complete graphics exchange specification) CAD file transfer format
CAD database of the structure needs to be generated. We is used for models to be exported to CAD and the STL
conducted the 3D reconstruction to arrive at a CAD-based format used to import models from CAD to the MedCAD

Figure 3 Flowchart for imaging-based CAD model generation


C 2004 Portland Press Ltd
Computer-aided tissue engineering: application to biomimetic modelling and design of tissue scaffolds 53

Figure 4 Reverse-engineering approach for developing a CAD-based femur model

system. It can be seen that not all features or details of the The final CAD model of the proximal femur structure
image can be exported to CAD, which would otherwise obtained by each of the process path is shown in Figure 5.
slow the system down. Basic features can be recognized and Notice that the femur structure obtained by the STL process
converted into geometrical entities such as cylinder, sphere, path has resulted in a poor CAD model. The smoother the
anatomical landmarks etc. B-Spline surfaces are also used to model, the lower the file sizes tend to be, and this can
make a real fit on a surface anatomical contour. be less frustrating when handling these models in CAD
software. The reverse-engineering method was followed
Process path 2: reverse-engineering method The 3D voxel for the CAD model generation of the homogenized femur
model created after segmentation is used as the starting domain structure, since this resulted in a much smoother
point for this method. The 3D voxel dataset of the bone and better model and, more importantly, had a smaller
structure is converted into point data form and then these CAD file size of around 10 MB for all the seven layers
points are loaded into any reverse-engineering software. The combined. The seven-layered CAD assembly structure of
commercially available software Geomagic Studios [11] was the proximal femur is also shown in Figure 5. A summary
then used to process these data points for surface processing of the comparison of each process path is presented in
and refinement. Application of this process path to develop Table 2.
a CAD-based femur model is outlined in Figure 4. This is
perhaps the best approach that can be followed, since the
process starts from the base level, i.e. points. Although
the model has a lot of processing time involved, the results Design and characterization of bone
obtained are significantly better than those obtained by the scaffold and tissue representative
other two methods. unit cells
Process path 3: the STL interface The 3D voxel model Cellular scaffold unit cells with various porosities and inter-
can also be converted into the STL file and this STL file can nal architectures can provide tailored mechanical and biolo-
then be imported into Geomagics for surface refinement gical properties. Here we use feature primitives in which
and non-uniform rational B-spline (NURBS) surface gene- each primitive discrete volume of the designed tissue scaffold
ration. The difference between this and the point data unit cell is represented by a specific feature which is bio-
method is that here a triangulated model is the starting mimetic to the internal architecture patterns of the re-
input format rather than the point data form of the model placed tissues. We further use the feature patterns and
structure. The process time involved is less but may be architectures to design desirable pores, pore sizes
suitable for only certain kinds of surfaces. and shapes, and its distribution in the scaffold internal

C 2004 Portland Press Ltd
54 W. Sun and others

Figure 5 CAD-based bone structure model

Table 2 Comparison of 3D reconstructive methods for generating a CAD-based femur model

3D reconstruction method Process File size Quality

Medical CAD Easiest and quickest, but may File size: medium Poor
not be suitable for complex IGES conversion process time: long
tissue geometry IGES: 266 kB
CAD (Pro/ENGINEER C
): 309 kB

Reverse engineering A longer process, but suitable Initial file sizes in the point form are not Best
for complex tissue geometry, high, but final CAD model may involve
since control is achieved at comparatively large file sizes
every level Point: 256 kB (around 7732 points)
IGES: 266 kB (102 NURBS patches)
CAD (Pro/ENGINEER C
): 298 kB

Stereolithography method Quick method to arrive at a Initial STL file size maybe high, resulting Average
CAD model, but not in large CAD model IGES file size
suitable for complex tissue STL: 1.82 MB (38252 triangles)
geometry; geometry not editable IGES: 9.83MB (2316 NURBS patches)
CAD (Pro/ENGINEER C
): 10.3 MB

structure, so the required mechanical and biological with four open pores on each face. This cellular-like scaffold
conditions can be met. We then select the specific feature unit cell model was generated by Pro/ENGINEER C
software,
primitive as the unit-cell internal architecture according to and converted into IGES format and then imported to
the required mechanical or biological functions, and use the ABAQUS for finite element analysis. The relationship of
heterogeneous CAD modelling approach to construct unit the porosity with the overall geometry of the unit cell
cells for bone scaffold, in considering the anatomical and for the homogeneous square unit cell with square pores,
topological requirements for bone replacement. Samples of is determined by:
CAD-based cellular-unit-cell-rendered images are shown in
N[{L ∗ l 2∗ (f /2)} − {(f /2 − 1) · l 3 · N/2}]
Figure 6. A finite element method (ABAQUS [12]) was then P = (4)
used to predict the unit-cell effective mechanical properties L3
as shown in Figure 7 for the unit cell with characteristic where N is the number of the pores in the unit cell, f is
geometrical parameters (Figure 7a), along with its applied the total number of faces that contain pores, L is the size of
boundary condition (Figure 7b) and the contour plot of the square unit cell and l is the size of pore (Figure 7a).
reaction force (Figure 7c). A total 8353 four-node tetrahedral elements were used
The geometry of the unit cell used in the finite element in the finite element analysis. A schematic illustration of
analysis is defined as a 4.5 mm × 4.5 mm × 4.5 mm block applying boundary conditions and loading conditions for

C 2004 Portland Press Ltd
Computer-aided tissue engineering: application to biomimetic modelling and design of tissue scaffolds 55

Figure 6 Samples of the designed scaffold unit cells

Figure 7 Finite element method for predicting unit cell stress and deformation

(a) Unit cell with characteristic geometrical parameters; (b) applied boundary conditions to the unit cell; (c) FEA (finite element analysis) contour plot for stress
distribution within the scaffold.

calculating effective Young’s modulus Exx is shown in Fig- where Ax is the area of cross-section of the face Sx2 and Rx is
ure 7(a). The face given by Sx1 is constrained in the x- the average reaction force on the surface Sx2 . Since the
direction i.e. Ux = 0 and the face given by Sx2 is given unit cell is symmetric in the x, y and z directions, we
a displacement of Ux = 0.001 Lx which is equivalent to obtain Exx = Eyy = Ezz = Eeffective . A summary of the results
ε x = 0.1 % where Lx is the length of the face. This boundary predicted by finite element method for scaffolds with various
condition is intended to obtain a uniform displacement field porosities at 26, 41, 59, 76 and 83 % levels for three
throughout the model in the x-direction, thus enabling us to different biomaterials {hydroxyapatite, PLGA [poly(DL-
calculate the effective E in the x-direction, Exx . The effective lactic-co-glycollic acid)] and PLLA [poly(L-lactic acid)]} is
Young’s modulus of the cell can then be obtained by using presented in Table 3 and further plotted in Figure 8.
the relationship given below: From the QCT characterization of the proximal femur,
 Rx  the bone Young’s modulus varies from 0.6 to 2.0 GPa.
σx Rx
Exx = =  USxx 2 =
A
(5) From a biological point of view, we know that a desirable
εx L
0.001 · Ax scaffold structure should have a porosity ranging from
x


C 2004 Portland Press Ltd
56 W. Sun and others

Table 3 Summary of results obtained by FEA

Effective modulus of unit cell at different porosity levels (GPa)

Material Young’s modulus (E ) (GPa) Porosity (%) . . . 26 41 59 76 83

Hydroxyapatite 2.0 1.362 0.9 0.6734 0.328 0.2764


PLLA 2.7 1.7466 1.2564 0.909 0.44 0.375
PLGA 4.1 2.652 1.7466 1.38 0.673 0.567

are anisotropic and can be determined through a composite


lamination theory. At the laminar level, a unit cell is used to
calculate the laminar effective properties. The average linear
stress-strain relations of the unit cell in the kth layer in this
model can be expressed by:
σ i , j = C ij pq εq p (6)
where

n    n
C i(k)3 C 3(k)j C 13(k)
C ij = α k C ij(k) − + α (k)

k=1
C 33(k) k=1
C 33(k)
 n −1
Figure 8 Effect of unit-cell material and porosity on unit-cell mechanical  n
C 3(l j)  α (k)
properties × α (l )
(l )
(i = 1,2,3 . . .) (7)
l =1
C 33 k=1 C 33(k)
L-PGA, PLGA; L-PLA, PLLA.
represents the average effective elastic tensor of the bone,
Cij the elastic components of the kth layer and α k = hk /h, with
55 to 70 %. In this regard, the unit cell made of hydroxy- h denoting the total height of the bone and hk the height of
apatite material with 59 % porosity and effective Young’s each layer.
modulus of 0.6734 GPa barely meets both biological and
mechanical requirements. PLLA-based unit cells with about Freeform fabrication of tissue scaffold
40–60 % porosity do give a better option as a scaffold
material for the proximal femur. Candidate unit cells can A sample process-planning scenario to design and fabricate
then be selected from the predicted curves shown in Fig- tissue scaffold structures is depicted in Figure 9. In the cus-
ure 8 in our review in this issue [2]. tom implant planning stage, the CT/MRI images of the de-
Once the appropriate unit cell has been identified fected region are obtained and reconstructed by the
with the matched porosity, interconnectivity and mechanical method as we have already outlined in the previous section.
properties, a contour bone structure reconstructed from Through reverse-engineering techniques, a CAD model
CT/MRI images will be filled in with the selected unit-cell of the region of interest is made. At the same time,
architecture. A constructive heterogeneous solid geometry mechanical characterization techniques would be employed
algebra [15,16] can be used to combine the unit-cell to obtain the mechanical properties of the region to be
architecture and the replaced bone anatomical structure replaced. On the basis of the characterization process
to achieve the final shape of the replaced bone tissue and biological requirements, an appropriate unit cell is
scaffold. An example of how a basic unit cell was intersected designed and, along with constructive heterogeneous solid-
within Geomagics software with a bone structure that geometry techniques, an appropriate scaffold structure
needs to be replaced to form a tissue scaffold of the exact obtained. The CAD file is then converted into a STEP
internal architecture and external anatomy is schematically (standard for exchange of product model data) file format
illustrated in Figure 8. with designed geometrical and material information [17,18].
We can also consider the structural heterogeneity of Using an appropriate 3D modelling kernel, the scaffold
bone as an n-layered laminated composite. This model is implant reconstructed from the STEP definitions is then
analogous to the real bone replacement/scaffold structure sliced according to the slice parameters set using the slice
produced through layered solid-freeform-fabrication tech- module of the software. The slice module based on the
nology [for example SLA (STL apparatus), LOM (laminated direct slicing approach would work on the basis of the B-
objective manufacturing) and 3D printing (3DP)]. The rep structure in the STEP file [19]. The slicing is achieved
overall effective mechanical properties of bone structure on the basis of the ray-casting method, where the object is

C 2004 Portland Press Ltd
Computer-aided tissue engineering: application to biomimetic modelling and design of tissue scaffolds 57

Figure 9 Flowchart of process planning for fabricating tissue scaffold

sliced by a series of parallel planes, each of the planes having metic design approach, for example, by converting the
rays cast out across them. The intersection points of the ray biomimetic designed scaffold internal architectures into
with the object define an entry point and exit point. A set of layered deposition patterns. This process eliminates mate-
these points defines raster lines. The slicing module defines rial preparation and indirect casting in the scaffold fabri-
the slice layers as scan raster lines to support the open- cation, thus opening opportunities for many biomaterial
end architecture that is required for the scaffold structures. applications.
Once these scan lines are defined, complete information that
consists of the slice layers as well as the material information
is stored in a print-job database that serves as a temporary Conclusions
storage as well as for future retrieval. The scan lines are
converted into machine-code instructions that are then sent This paper presents an application of the CATE approach for
to the machine for fabrication. biomimetic modelling and design of a bone-tissue engineered
A sample of cellular poly(6-hexanolactone) [poly(ε- structure. The process of the modelling development,
caprolactone)] scaffold fabricated by our in-house-deve- QCT characterization method, tissue representative unit-
loped micronozzle-freeform-extruding-deposition system is cell structural analysis and a CAD-based scaffold bone
shown in Figure 7 of [20]. The scanning-electron-micro- design have been described. Results of the effect of the
scopic characterization shows that the thus fabricated scaf- unit-cell materials and the designed porosities on the unit-
fold micro-architectures could be achieved at about cell mechanical properties for hydroxyapatite, PLGA and
250 µm scale level with excellent uniformity of the fill gaps, PLLA materials have been given. The CATE approach
the depositing struts, and the internal pore connectivity as presented provides an effective tool for modelling, design
shown in Figure 7 of [20]. This extruding deposition process and fabrication of complex bone-tissue scaffolds under
directly fabricates the designed bone tissue scaffolds ac- multiple biological and biophysical design constraints. The
cording to the design specifications defined in the bio/ calculated E from the characterization is in accordance with
tissue informatics modelling developed through the biomi- published data for cancellous bone in the range 0.5–1.5 GPa.

C 2004 Portland Press Ltd
58 W. Sun and others

It is noteworthy that both cancellous and cortical bone References


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Acknowledgements 20 Wang, F., Shor, L., Darling, A., Khalil, S., Sun, W., Güçeri, S. and
Lau, A. (2004) Rapid Prototyping J., in the press
This research was partially supported by the National
Received 1 July 2003/30 September 2003; accepted 14 October 2003
Science Foundation through grant 0219176, and by Therics Published as Immediate Publication 14 October 2003, DOI 10.1042/BA20030109
Inc., Princeton, NJ, U.S.A.

C 2004 Portland Press Ltd

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