Functionally graded additive manufacturing to achieve functionality specifications of osteochondral scaffolds

Evaluating the effect of printing parameters on the performance of resin occlusal splints for a sustainable dentistry

Bruxism affects millions worldwide, leading to dental damage like worn teeth and tooth loss. Resin 3D printing presents a promising method for creating intricate, comfortable, and durable occlusal splints. This study examines how printing parameters-layer thickness, orientation angle, and curing time-affect the mechanical (compressive strength, wear rate, impact strength) and physical (water sorption, surface roughness, dimensional accuracy) properties of occlusal splints made from a methacrylate-based resin. A total of 120 specimens were produced according to American Society for Testing and Materials (ASTM) standards using different parametric combinations. The response surface methodology (RSM) was applied to optimize key parameters. The optimum printing parameters for compressive strength include a layer height of 16.5 mm, curing time of 93.6 min, an orientation angle of 12.8º, yielding a compressive strength of 9.05 MPa, wear rate of 159 mm3/min, and impact strength of 71.58 J/m. Similarly, the optimum results for minimum surface roughness (8.013 microns), maximum dimensional accuracy (97.67 and minimum water sorption (0.386%) are achieved at a layer thickness of 16 mm, curing time of 93 min, and orientation angle of 12º. Results show that optimizing resin 3D printing parameters for occlusal splints significantly reduces production costs, particularly in regions with limited access to dental care, while promoting sustainable dental solutions by minimizing the environmental impact of traditional manufacturing methods and enhancing the efficiency of splint production.

Additive Manufacturing of Biomaterials-Design Principles and Their Implementation

Additive manufacturing (AM, also known as 3D printing) is an advanced manufacturing technique that has enabled progress in the design and fabrication of customised or patient-specific (meta-)biomaterials and biomedical devices (e.g., implants, prosthetics, and orthotics) with complex internal microstructures and tuneable properties. In the past few decades, several design guidelines have been proposed for creating porous lattice structures, particularly for biomedical applications. Meanwhile, the capabilities of AM to fabricate a wide range of biomaterials, including metals and their alloys, polymers, and ceramics, have been exploited, offering unprecedented benefits to medical professionals and patients alike. In this review article, we provide an overview of the design principles that have been developed and used for the AM of biomaterials as well as those dealing with three major categories of biomaterials, i.e., metals (and their alloys), polymers, and ceramics. The design strategies can be categorised as: library-based design, topology optimisation, bio-inspired design, and meta-biomaterials. Recent developments related to the biomedical applications and fabrication methods of AM aimed at enhancing the quality of final 3D-printed biomaterials and improving their physical, mechanical, and biological characteristics are also highlighted. Finally, examples of 3D-printed biomaterials with tuned properties and functionalities are presented.

Cytotoxicity and Ion Release of Functionally Graded Al₂O₃- Ti Orthopedic Biomaterial

The aim of this study was to evaluate the biocompatibility of Al2O3-Ti functionally graded material (FGM) successfully fabricated by Spark Plasma Sintering (SPS) technology, and to compare with pure Ti and alumina. Pre-osteoblast MC3T3-E1 cells were used to examine cell viability, proliferation and differentiation using lactate dehydrogenase (LDH) cytotoxicity detection kit, MTT assay and Alkaline Phosphatase (ALP) colorimetric test at different time points. Furthermore, ion release from the materials into the culture medium was assessed. The results showed cell viability over 80% for FGM and alumina which dismissed any cytotoxicity risk due to materials or manufacturing. The results of MTT tests identified superiority of FGM than Ti and alumina, particularly in late proliferation. Nevertheless, in cell differentiation, all materials performed similarly with no statistical differences. Furthermore, it was indicated that Ti had no ion release, while alumina had small amount of Al ion dissolution. FGM, however, had more ions detachment, particularly Al ions.

Fractal Design Boosts Extrusion-Based 3D Printing of Bone-Mimicking Radial-Gradient Scaffolds

Although extrusion-based three-dimensional (EB-3D) printing technique has been widely used in the complex fabrication of bone tissue-engineered scaffolds, a natural bone-like radial-gradient scaffold by this processing method is of huge challenge and still unmet. Inspired by a typical fractal structure of Koch snowflake, for the first time, a fractal-like porous scaffold with a controllable hierarchical gradient in the radial direction is presented via fractal design and then implemented by EB-3D printing. This radial-gradient structure successfully mimics the radially gradual decrease in porosity of natural bone from cancellous bone to cortical bone. First, we create a design-to-fabrication workflow with embedding the graded data on basis of fractal design into digital processing to instruct the extrusion process of fractal-like scaffolds. Further, by a combination of suitable extruded inks, a series of bone-mimicking scaffolds with a 3-iteration fractal-like structure are fabricated to demonstrate their superiority, including radial porosity, mechanical property, and permeability. This study showcases a robust strategy to overcome the limitations of conventional EB-3D printers for the design and fabrication of functionally graded scaffolds, showing great potential in bone tissue engineering.

Polymer 3D Printing Review: Materials, Process, and Design Strategies for Medical Applications

Polymer 3D printing is an emerging technology with recent research translating towards increased use in industry, particularly in medical fields. Polymer printing is advantageous because it enables printing low-cost functional parts with diverse properties and capabilities. Here, we provide a review of recent research advances for polymer 3D printing by investigating research related to materials, processes, and design strategies for medical applications. Research in materials has led to the development of polymers with advantageous characteristics for mechanics and biocompatibility, with tuning of mechanical properties achieved by altering printing process parameters. Suitable polymer printing processes include extrusion, resin, and powder 3D printing, which enable directed material deposition for the design of advantageous and customized architectures. Design strategies, such as hierarchical distribution of materials, enable balancing of conflicting properties, such as mechanical and biological needs for tissue scaffolds. Further medical applications reviewed include safety equipment, dental implants, and drug delivery systems, with findings suggesting a need for improved design methods to navigate the complex decision space enabled by 3D printing. Further research across these areas will lead to continued improvement of 3D-printed design performance that is essential for advancing frontiers across engineering and medicine.

Challenges on optimization of 3D-printed bone scaffolds

Advances in biomaterials and the need for patient-specific bone scaffolds require modern manufacturing approaches in addition to a design strategy. Hybrid materials such as those with functionally graded properties are highly needed in tissue replacement and repair. However, their constituents, proportions, sizes, configurations and their connection to each other are a challenge to manufacturing. On the other hand, various bone defect sizes and sites require a cost-effective readily adaptive manufacturing technique to provide components (scaffolds) matching with the anatomical shape of the bone defect. Additive manufacturing or three-dimensional (3D) printing is capable of fabricating functional physical components with or without porosity by depositing the materials layer-by-layer using 3D computer models. Therefore, it facilitates the production of advanced bone scaffolds with the feasibility of making changes to the model. This review paper first discusses the development of a computer-aided-design (CAD) approach for the manufacture of bone scaffolds, from the anatomical data acquisition to the final model. It also provides information on the optimization of scaffold's internal architecture, advanced materials, and process parameters to achieve the best biomimetic performance. Furthermore, the review paper describes the advantages and limitations of 3D printing technologies applied to the production of bone tissue scaffolds.

Ultrasonic mixing chamber as an effective tool for the biofabrication of fully graded scaffolds for interface tissue engineering

One of the main challenges of the interface-tissue engineering is the regeneration of diseased or damaged interfacial native tissues that are heterogeneous both in composition and in structure. In order to achieve this objective, innovative fabrication techniques have to be investigated. This work describes the design, fabrication, and validation of a novel mixing system to be integrated into a double-extruder bioprinter, based on an ultrasonic probe included into a mixing chamber. To validate the quality and the influence of mixing time, different nanohydroxyapatite–gelatin samples were printed. Mechanical characterization, micro-computed tomography, and thermogravimetric analysis were carried out. Samples obtained from three-dimensional bioprinting using the mixing chamber were compared to samples obtained by deposition of the same final solution obtained by manually operated ultrasound probe, showing no statistical differences. Results obtained from samples characterization allow to consider the proposed mixing system as a promising tool for the fabrication of graduated structures which are increasingly being used in interface-tissue engineering.

Compressive characteristics of radially graded porosity scaffolds architectured with minimal surfaces

Scaffolds with gradient pore characteristics have received a great deal of attention as they can better mimic the structure of the native tissues and concurrently meet both biological and mechanical requirements. In the present study, the effects of porosity geometry and porosity gradient patterns on the deformation mechanism and compressive mechanical properties of the structures were investigated in the context of stretching (I-WP and P surfaces) versus bending dominated (D surface) triply periodic minimal surface (TPMS) based architectures. Different gradient patterns were found to significantly alter the deformation mechanism. Radial gradient patterns (perpendicular to loading direction) provide higher deformability while longitudinally graded scaffolds suffer from low failure strain. In the stretching dominated architectures vertical cracks propagated under compression due to the materials transverse expansion under compression. Deformations in the bending dominated architectures, however, were accompanied by a progressive collapse owing to the shearing of the struts. In general, stretching dominated structures showed the higher mechanical properties and provided more efficiency under mechanical loads. Finite Element simulations also demonstrated a high capability for predicting the deformation as well as mechanical responses (especially for elastic properties) and can be used as a tool for designing multifunctional gradient porous scaffolds.