Optimized 3D-Printed Polylactic Acid/Graphene Oxide Scaffolds for Enhanced Bone Regeneration

BACKGROUND: Three-dimensional (3D) printed scaffolds have emerged as promising tools for bone regeneration, but the optimal structural design and pore size remain unclear. Polylactic acid (PLA) reinforced with graphene oxide (GO) offers enhanced mechanical and biological performance, yet systematic evaluation of architecture and pore size is limited. METHODS: Two scaffold architectures (lattice-type and dode-type) with multiple pore sizes were fabricated using UV-curable PLA/GO resin. Physical accuracy, porosity, and mechanical properties were assessed through compression and fatigue testing. Based on in vitro screening, four pore sizes (930 μm, 690 μm, 558 μm, 562 μm) within the dode-type structure were analyzed. The 558 μm and 562 μm scaffolds, showing distinct fracture thresholds, were further evaluated in rat and rabbit calvarial defect models for inflammation and bone regeneration. RESULTS: In vitro testing revealed that while 930 μm and 690 μm scaffolds exhibited superior compressive strength, the 562 μm scaffold showed a unique critical fracture behavior, and the 558 μm scaffold offered comparable stability with higher resistance to premature failure. In vivo studies confirmed excellent biocompatibility in both groups, with early bone formation favored in the 558 μm scaffold and more continuous and mature bone observed in the 562 μm scaffold at later stages. CONCLUSIONS: This stepwise strategy-from structural design to pore size screening and preclinical validation-demonstrates that threshold-level mechanical properties can influence osteogenesis. PLA/GO scaffolds optimized at 558 μm and 562 μm provide a translationally relevant balance between mechanical stability and biological performance for bone tissue engineering.