Novel fabrication techniques to produce microspheres by thermally induced phase separation for tissue engineering and drug delivery

A novel application of thermally induced phase separation (TIPS) is described enabling the rapid formation of monodisperse porous microspheres. By taking advantage of TIPS processing parameters, the porosity, the pore morphology (bimodal/channel-like/radial towards the centre) and the presence of an open-pore or dense skin region can be tailored. Achievable sizes range from 10 to 2000 μm in diameter. The technique facilitates the homogeneous inclusion of particulate fillers and drugs. Moreover, the combined TIPS/oil-in-water emulsion technique allows for the production of microspheres with isotropic pore morphology with interconnected spherical pores of 30–70 μm and well-formed porous microspheres of 10–200 μm in diameter with an open porous surface. This method is advantageous over existing techniques by avoiding the use of long-term exposure to an aqueous continuous phase as used in oil-in-water or water-in-oil-in-water processing and therefore drug encapsulation efficiencies will be higher.