The present study reports foaming of polycaprolactone (PCL) and PCL nano- and micro-composites with dispersed hydroxyapatite (HA) particles by means of binary mixtures of supercritical CO2 (scCO(2)) and either ethyl lactate (EL) or ethyl acetate (EA) as plasticizer. The effect of the size and concentration of HA particles, as well as the effects of the plasticizer type and the incorporation route were investigated aiming to fabricate porous scaffolds with uniform morphology and controlled pore size distribution. For this purpose, foaming experiments were carried out by selecting two operating temperatures, 40 and 45 degrees C, and two soaking times, 1 and 17 h. Furthermore, a double step of depressurization was used to promote the development of a double-scale pore size structure in porous scaffolds useful for tissue engineering. The results of this study indicated that supercritical foaming of PCL and PCL-HA composites is enhanced when the selected operating temperature and time are 45 degrees C and 17 h, respectively. Furthermore, although both EL and EA plasticizers enhanced the low temperature foaming of the materials, we demonstrated that the route of incorporation of the plasticizer is a critical aspect for enhancing composite foaming and scaffold fabrication. From this point of view, the best results were achieved when EA was pre-mixed with the polymeric powder for preparing a dough for the foaming process. (C) 2014 Elsevier B.V. All rights reserved.