Physical and biocompatibility properties of poly-epsilon-caprolactone produced using in situ polymerisation: a novel manufacturing technique for long-fibre composite materials

Preliminary investigations into a novel process for the production of poly- epsilon-caprolactone (PCL) to be used as a matrix material in a bioabsorbab le composite material are detailed. This material is primarily being develo ped as a bone substitute for use in maxillofacial reconstructive surgery, h owever, the technique described could be adapted to other areas where bioab sorbable composite materials may be used. The development of a totally bioa bsorbable long-fibre composite material would allow a two-stage degradation to occur with the matrix material degrading first leaving a scaffold struc ture of degradable fibres which would be absorbed at a later stage. Caprola ctone monomer was polymerised in situ within a tool cavity to produce a net shape moulding. Inclusion of a fibre preform within the tool cavity which was impregnated by the liquid monomer produces a long-fibre composite mater ial. PCL with a range of molecular weights has been produced using this liq uid moulding technique to assess the physical and biocompatibility properti es compared to commercially available PCL, Osteoblast-like cells derived fr om human craniofacial bone (CFC) have been used to assess the in vitro bioc ompatibility of the PCL. The results show that high-quality PCL with a narr ow molecular weight distribution and properties similar to commercially ava ilable PCL can be produced using this technique. Polymerisation of the mono mer around a woven fibre preform made of a poly(lactic acid) (PLA)/poly(gly colic acid) (PGA) copolymer (vicryl mesh) produced a bioabsorbable long-fib re composite material. Further work is ongoing to develop this system towar ds a method for improving craniofacial bone reconstruction. (C) 2000 Elsevi er Science Ltd. All rights reserved.