Plasma‐Enabled Multiscale Coupling of Gyroid Architecture and Silver Nanoparticle Biointerfaces Drives Osteogenesis in 3D‐Printed Scaffolds

ABSTRACT

Engineering functional bone scaffolds can be enhanced by integrating biologically instructive nanoscale surface features (e.g., nanotopography and nanoroughness), micro‐scale geometric cues (e.g., curvature and porosity), and macro‐scale mechanical properties (e.g., bulk stiffness); however, these length scales are often optimized independently. Here, we present a multiscale design framework combining additive manufacturing of triply periodic minimal surface (TPMS) gyroid scaffolds with plasma‐assisted nanoscale surface engineering to regulate osteogenesis. Controlled variation in strut thickness generates distinct architectural regimes with coupled changes in curvature, porosity, and compressive modulus, recapitulating key aspects of trabecular bone mechanics. Micro‐computed tomography confirms trabecular bone‐like features, while finite element modeling and compression testing reveal that thinner architectures (0.6 mm) exhibit curvature‐preserving geometry and distributed stress profiles favorable for cellular interaction. A low‐temperature plasma electroless reduction (PER) strategy enables controlled silver nanoparticle (AgNP) deposition, while polydopamine (PDA) ensures uniform, cytocompatible coatings. Notably, PDA‐AgNP‐functionalized 0.6 mm scaffolds exhibit enhanced cytoskeletal organization, mineralization, and osteogenic gene expression, accompanied by elevated reactive oxygen species (ROS) and YAP/TAZ ‐associated transcriptional activity. These findings support cross‐scale coupling of architecture and nanoscale biointerfaces as a design framework for osteogenic scaffolds.