Abstract
Biodegradable scaffolds serve a central role in many strategies for engineering tissue replacements or in guiding tissue regeneration. Typically, these scaffolds function to create and maintain a space and to provide a support for cell adhesion. However, these scaffolds also can serve as vehicles for the delivery of bioactive factors (e.g., protein or DNA) in order to manipulate cellular processes within the scaffold microenvironment. This study presents a novel approach to fabricate tissue‐engineering scaffolds capable of sustained drug delivery whereby drug‐loaded microspheres are fabricated into structures with controlled porosity. A double‐emulsion process was used to fabricate microspheres with encapsulated DNA that retained its integrity and was released from the microspheres within 24 h. These DNA‐loaded microspheres subsequently were formed into a nonporous disk or an interconnected open‐pore scaffold (>94% porosity) via a gas‐foaming process. The disks and scaffolds exhibited sustained plasmid release for at least 21 days and had minimal burst during the initial phase of release. This approach of assembling drug‐loaded microspheres into porous and nonporous structures may find great utility in the fabrication of synthetic matrices that direct tissue formation. © 2001 Wiley Periodicals, Inc. J Biomed Mater Res 59: 349–356, 2002