The production of mechanically reliable scaffolds from bioceramics for use in bone tissue engineering remains challenging. This paper describes the establishment of optimal processing parameters of Bioglass (R) scaffolds using the replication/slurry-dip-coating technique, based on theoretical design and experimental investigation. The foams fabricated under the optimized conditions, i.e., 5-20 mu m particles and sintering at 1000 degrees C-1100 degrees C for 1-2 h, showed reproducible mechanical properties that could be predicted by Gibson and Ashby's theory. Excessively small (nano-sized) or overly large (> 30 mu m) particles both resulted in poor quality scaffolds with unsatisfactory mechanical performance, due to a high population of microcracks in struts and poor fusion between particles during sintering, respectively. In conclusion, a mechanically reliable scaffold can be achieved using Bioglass (R) and the replication/slurry-dip-coating technique, provided that the particle size of the Bioglass powder is within the range of 5-20 mu m and an appropriate sintering program (1000 degrees C-1100 degrees C, 12 h) is used.