This thesis is concerned with the design of a novel system for inserting porogen particles within internal structure of the bone scaffold. The proposed system would be integrated with a 3D printing machine to create macro-pores based on the conventional porogen leaching method. The system is capable of inserting porogens on pre-designed locations within the scaffold structure to realize the generation of macro-porosity within scaffolds. Several alternatives for such a porogen insertion mechanism are proposed based on employing a mechanical actuator for opening and closing the path of porogen particles from a porogen reservoir to the build chamber. Another possible design that offers significant advantages over its actuator-based alternatives is a pneumatic-based mechanism that picks up porogens from a porogen reservoir and places them at pre-designed locations. Among all the presented alternatives, the pneumatic-based system is selected by utilizing the value matrix method, and detail design of the different parts of this system is presented. The required pilot test setups for performing the feasibility study of the proposed method have been designed and successfully developed, and the practicality of the designed porogen insertion mechanism is proven through experiment.

This thesis is concerned with the design of a novel system for inserting porogen particles within internal structure of the bone scaffold. The proposed system would be integrated with a 3D printing machine to create macro-pores based on the conventional porogen leaching method. The system is capable of inserting porogens on pre-designed locations within the scaffold structure to realize the generation of macro-porosity within scaffolds. Several alternatives for such a porogen insertion mechanism are proposed based on employing a mechanical actuator for opening and closing the path of porogen particles from a porogen reservoir to the build chamber. Another possible design that offers significant advantages over its actuator-based alternatives is a pneumatic-based mechanism that picks up porogens from a porogen reservoir and places them at pre-designed locations. Among all the presented alternatives, the pneumatic-based system is selected by utilizing the value matrix method, and detail design of the different parts of this system is presented. The required pilot test setups for performing the feasibility study of the proposed method have been designed and successfully developed, and the practicality of the designed porogen insertion mechanism is proven through experiment.