Abstract
Reconstruction of the nipple–areola complex (NAC) following mastectomy is essential for both emotional and psychological recovery. Current clinical approaches are limited by loss of projection, poor mechanical stability, and absence of sensation. Additive manufacturing and tissue engineering enables the development of hybrid scaffolds that maintain long-term projection and support the restoration of sensation. This study aims to address these challenges by developing a novel 3D-printed polycaprolactone (PCL)-based scaffold, enhanced with conductive and biomimetic modifications.
PCL scaffolds were fabricated via melt extrusion and surface treated with cold atmospheric plasma (CAP) to enhance hydrophilicity. Conductive nanofibrous mats composed of poly (vinyl alcohol) (PVA) and PEDOT:PSS were electrospun, and collagen coating applied to enhance bioactivity. These mats were combined with the CAP-treated PCL scaffolds to form hybrid tissue engineered constructs. The integration of conductive and collagen-based surface layers aims to promote both neural reconnection and tissue integration, addressing sensory restoration alongside mechanical form.
Morphological analysis showed porosity ranged between ~70–80%, with pore sizes increasing with strand spacing. This strongly influenced mechanical performance, as the storage modulus decreased with larger pores, consistent with the mechanical behaviour of porous structures. Dynamic mechanical analysis confirmed that the PCL scaffolds maintained stiffness within soft tissue ranges, yet sufficient for projection stability. Preliminary electrospinning trials showed good spinnability, supporting feasibility for conductive surface integration, though further optimisation is needed. Ongoing work will focus on completing surface wettability analysis through water contact analysis, and optimising electrospun conductive mats for integration with the PCL framework. Later studies will assess cellular compatibility and electrical performance to confirm the scaffold’s potential for functional NAC regeneration.
This multifunctional scaffold offers a versatile platform for NAC regeneration. Through the integration of 3D melt extrusion and electrospinning, our hybrid biofabrication approach achieves both structural stability and electrical conductivity, enhancing bioactivity and supporting long-term projection with potential for innervation and sensory restoration.