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Osteonecrosis of the femoral head (ONFH) is a disease that affects young adults in their thirties to fifties, representing the progressive destruction of the hip bone caused by deficient vascularization. As the condition slowly leads to complete collapse of the femoral head, the conventional solution is total hip arthroplasty. Thin scaffolds consisting of fiber-reinforced hydrogels could be used to regenerate the affected bone surface, coupled with hip resurfacing for less invasive approaches. Melt electrowriting (MEW) was used to produce polycaprolactone (PCL) reinforcing elements for thin scaffolds, with four mesh densities and highly tunable mechanical properties. The influence of the MEW process parameters on the PCL filaments’ morphology was investigated using Design of Experiments to optimize their fabrication and obtain tailorable structures with entangled fiber morphology for increased contact surface with the hydrogel component. Uniaxial tensile tests were performed to investigate the difference in tensile properties of the entangled design versus the aligned counterparts, including the exploration of the mesh size effect. The microstructure and microstructural changes of the entangled meshes at uniaxial tensile deformation were explored using micro-computed tomography. Plasma treated meshes were embedded in gelatin methacryloyl/alginate hydrogels, developing reinforced composite scaffolds with potential for bone surface reconstruction.

This study explores the potential utilization of walstromite (BaCa2Si3O9) as a foundational material for creating new bioceramics in the form of scaffolds through 3D printing technology. To achieve this objective, this study investigates the chemical–mineralogical, morphological, and structural characteristics, as well as the biological properties, of walstromite-based bioceramics. The precursor mixture for walstromite synthesis is prepared through the sol–gel method, utilizing pure reagents. The resulting dried gelatinous precipitate is analyzed through complex thermal analysis, leading to the determination of the optimal calcination temperature. Subsequently, the calcined powder is characterized via X-ray diffraction and scanning electron microscopy, indicating the presence of calcium and barium silicates, as well as monocalcium silicate. This powder is then employed in additive 3D printing, resulting in ceramic scaffolds. The specific ceramic properties of the scaffold, such as apparent density, absorption, open porosity, and compressive strength, are assessed and fall within practical use limits. X-ray diffraction analysis confirms the formation of walstromite as a single phase in the ceramic scaffold. In vitro studies involving immersion in simulated body fluid (SBF) for 7 and 14 days, as well as contact with osteoblast-like cells, reveal the scaffold’s ability to form a phosphate layer on its surface and its biocompatibility. This study concludes that the walstromite-based ceramic scaffold exhibits promising characteristics for potential applications in bone regeneration and tissue engineering.