Polylactic Acid (PLA) Foaming: Design of Experiments for Cell Size Control

Abstract

In this study, a design of experiments (DoE) approach was used to develop a PLA open-cell foam morphology using the compression molding technique. The effect of three molding parameters (foaming time, mold opening temperature, and weight concentration of the ADA blowing agent) on the cellular structure was investigated. A regression equation relating the average cell size to the above three processing parameters was developed from the DoE and the analysis of variance (ANOVA) was used to find the best dimensional fitting parameters based on the experimental data. With the help of the DoE technique, we were able to develop various foam morphologies having different average cell size distribution levels, which is important in the development of open-cell PLA scaffolds for bone regeneration for which the control of cell morphology is crucial for osteoblasts proliferation. For example, at a constant ADA weight concentration of 5.95 wt%, we were able to develop a narrow average cell size distribution ranging between 275 and 300 μm by varying the mold opening temperature between 106°C and 112°C, while maintaining the foaming time constant at 8 min, or by varying the mold foaming time between 6 and 11 min and maintaining the mold opening temperature at 109°C.