There are several methods of producing open porous polymer structures for medical use. However, very few are applicable to industries and are therefore limited to both number of samples and batch variations. This study presents an industrial microcellular injection molding process, known as MuCell® technology, which was used to produce highly porous scaffolds of thermoplastic polyurethane. A parameter study was performed to quantify and analyze the effect of the processing parameters on the porous structure. Six key parameters (gas content, weight reduction, injection speed, mold temperature, plasticizing pressure, and temperature) were tested with an iteration method. The pore structure was determined with advanced micro Computer Tomography algorithm. All key processing parameters were identified. Gas content and weight reduction showed a more profound effect on the pore morphology than other parameters on the pore structure. It was possible to produce scaffolds with open porosity as high as 71%. The study concludes that MuCell® technology is an accurate and liable production method for large-scale production of open porous thermoplastic polyurethane scaffolds, and supercritical fluid could, therefore, be a potential production method for polymer scaffolds.
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