3D printing for the integration of porous materials into miniaturised fluidic devices: A review

3D digital light process bioprinting: Cutting-edge platforms for resolution of organ fabrication

Research in the field of regenerative medicine, which replaces or restores the function of human damaged organs is advancing rapidly. These advances are fostering important innovations in the development of artificial organs. In recent years, three-dimensional (3D) bioprinting has emerged as a promising technology for regenerative medicine applications. Among various techniques, digital light process (DLP) 3D bioprinting stands out for its ability to precisely create high-resolution, structurally complex artificial organs. This review explores the types and usage trends of DLP printing equipment, bioinks, and photoinitiators. Building on this foundation, the applications of DLP bioprinting for creating precise microstructures of human organs and for regenerating tissue and organ models in regenerative medicine are examined. Finally, challenges and future perspectives regarding DLP-based bioprinting, particularly for precision printing applications in regenerative medicine, are discussed.

Cultivation of Bovine Mesenchymal Stem Cells on Plant-Based Scaffolds in a Macrofluidic Single-Use Bioreactor for Cultured Meat

Reducing production costs, known as scaling, is a significant obstacle in the advancement of cultivated meat. The cultivation process hinges on several key components, e.g., cells, media, scaffolds, and bioreactors. This study demonstrates an innovative approach, departing from traditional stainless steel or glass bioreactors, by integrating food-grade plant-based scaffolds and thermoplastic film bioreactors. While thermoplastic films are commonly used for constructing fluidic systems, conventional welding methods are cost-prohibitive and lack rapid prototyping capabilities, thus inflating research and development expenses. The developed laser welding technique facilitates contamination-free and leakproof sealing of polyethylene films, enabling the efficient fabrication of macrofluidic systems with various designs and dimensions. By incorporating food-grade plant-based scaffolds, such as rice seeded with bovine mesenchymal stem cells, into these bioreactors, this study demonstrates sterile cell proliferation on scaffolds within macrofluidic systems. This approach not only reduces bioreactor prototyping and construction costs but also addresses the need for scalable solutions in both research and industrial settings. Integrating single-use bioreactors with minimal shear forces and incorporating macro carriers such as puffed rice may further enhance biomass production in a scaled-out model. The use of food-grade plant-based scaffolds aligns with sustainable practices in tissue engineering and cultured-meat production, emphasizing its suitability for diverse applications.

A review of the recent achievements and future trends on 3D printed microfluidic devices for bioanalytical applications

3D printing has revolutionized the manufacturing process of microanalytical devices by enabling the automated production of customized objects. This technology promises to become a fundamental tool, accelerating investigations in critical areas of health, food, and environmental sciences. This microfabrication technology can be easily disseminated among users to produce further and provide analytical data to an interconnected network towards the Internet of Things, as 3D printers enable automated, reproducible, low-cost, and easy fabrication of microanalytical devices in a single step. New functional materials are being investigated for one-step fabrication of highly complex 3D printed parts using photocurable resins. However, they are not yet widely used to fabricate microfluidic devices. This is likely the critical step towards easy and automated fabrication of sophisticated, complex, and functional 3D-printed microchips. Accordingly, this review covers recent advances in the development of 3D-printed microfluidic devices for point-of-care (POC) or bioanalytical applications such as nucleic acid amplification assays, immunoassays, cell and biomarker analysis and organs-on-a-chip. Finally, we discuss the future implications of this technology and highlight the challenges in researching and developing appropriate materials and manufacturing techniques to enable the production of 3D-printed microfluidic analytical devices in a single step.

3D-printed stereolithographic fluidic devices for automatic nonsupported microelectromembrane extraction and clean-up of wastewater samples

BACKGROUND

There is a quest of novel functional and reliable platforms for enhancing the efficiency of microextraction approaches in troublesome matrices, such as industrial wastewaters. 3D printing has been proven superb in the analytical field to act as the springboard of microscale extraction approaches.

RESULTS

In this work, low-force stereolithography (SL) was exploited for 3D printing and prototyping bespoke fluidic devices for accommodating nonsupported microelectromembrane extraction (μEME). The analytical performance of 3D-printed μEME devices with distinct cross-sections, including square, circle, and obround, and various channel dimensions was explored against that of commonly used circular polytetrafluoroethylene (PTFE) tubing in flow injection systems. A computer-controlled millifluidic system was harnessed for the (i) automatic liquid-handling of minute volumes of donor, acceptor, and organic phases at the low μL level that spanned from 3 to 44 μL in this work, (ii) formation of three-phase μEME, (iii) in-line extraction, (iv) flow-through optical detection of the acceptor phase, and (v) solvent removal and regeneration of the μEME device and fluidic lines. Using methylene blue (MB) as a model analyte, experimental results evinced that the 3D-printed channels with an obround cross-section (2.5 mm × 2.5 mm) were the most efficient in terms of absolute extraction recovery (59%), as compared to PTFE tubing of 2.5 mm inner diameter (27%). This is attributed to the distinctive convex interface of the organic phase (1-octanol), with a more pronounced laminar pattern, in 3D-printed SL methacrylate-based fluidic channels against that of PTFE tubing on account of the enhanced 1-octanol wettability and lower contact angles for the 3D-printed devices. The devices with obround channels were leveraged for the automatic μEME and in-line clean-up of MB in high matrix textile dyeing wastewater samples with relative recoveries ≥81%, RSD% ≤ 17.1% and LOD of 1.3 mg L-1. The 3D-printed nonsupported μEME device was proven superb for the analysis of wastewater samples with an elevated ionic strength (0.7 mol L-1 NaCl, 5000 mg L-1 Na2CO3, and 0.013 mol L-1 NaOH) with recorded electric currents below 12 μA.

NOVELTY

The coupling of 3D printing with nonsupported μEME in automatic flow-based systems is herein proposed for the first time and demonstrated for the clean-up of troublesome samples, such as wastewaters.

3D-printed extraction devices fabricated from silica particles suspended in acrylate resin

In recent years, there has been an increasing worldwide interest in the use of alternative sample preparation methods. Digital light processing (DLP) is a 3D printing technique based on using UV light to form photo-curable resin layer upon layer, which results in a printed shape. This study explores the application of this technique for the development of novel drug extraction devices in analytical chemistry. A composite material consisting of a photocurable resin and C18-modified silica particles was employed as a sorbent device, demonstrating its effectiveness in pharmaceutical analysis. Apart from estimating optimal printing parameters, microscopic examination of the material surface, and sorbent powder to resin ratio, the extraction procedure was also optimised. Optimisation included the type and amount of sample matrix additives, desorption solvent, sorption and desorption times, and proper number of sorbent devices needed in extraction protocol. To demonstrate this method's applicability for sample analysis, the solid-phase extraction followed by gas chromatography coupled with mass spectrometry (SPE-GC-MS) method was validated for its ability to quantify benzodiazepine-type drugs. This evaluation confirmed good linearity in the concentration range of 50-1000 ng/mL, with R2 values being 0.9932 and 0.9952 for medazepam and diazepam, respectively. Validation parameters proved that the presented method is precise (with values ranging in-between 2.98 %-7.40 %), and accurate (88.81 % to 110.80 %). A negative control was also performed to investigate possible sorption properties of the resin itself, proving that the addition of C18-modified silica particles significantly increases the extraction efficiency and repeatability. The cost-effectiveness of this approach makes it particularly advantageous for single-use scenarios, eliminating the need for time-consuming sorbent-cleaning procedures, common in traditional solid-phase extraction techniques. Future optimisation opportunities include refining sorbent size, shape, and geometry to achieve lower limits of quantification. As a result of these findings, 3D-printed extraction devices can serve as a viable alternative to commercially available SPE or solid-phase microextraction (SPME) protocols for studying new sample preparation approaches.

Technological Advancement and Trend in Selective Bioanalytical Sample Extraction through State of the Art 3-D Printing Techniques Aiming 'Sorbent Customization as per need'

The inherent complexity of biological matrices and presence of several interfering substances in biological samples make them unsuitable for direct analysis. An effective sample preparation technique assists in analyte enrichment, improving selectivity and sensitivity of bioanalytical method. Because of several key benefits of employing 3D printed sorbent in sample extraction, it has recently gained popularity across a variety of industries. Applications for 3D printing in the field of bioanalytical research have grown recently, particularly in the areas of miniaturization, (bio)sensing, sample preparation, and separation sciences. Due to the high expense of the solid phase microextraction cartridge, researcher approaches in-lab production of sorbent material for the extraction of analyte from biological samples. Owing to its distinct advantages such as low costs, automation capabilities, capacity to produce products in a variety of shapes, and reduction of tedious steps of sample preparation, 3D printed sorbents are gaining increased attention in the field of bioanalysis. It is also reported to offer high selectivity and assist in achieving a much lower limit of detection. In this review, we have discussed current advancements in different types of 3D printed sorbents, production methods, and their applications in the field of bioanalytical sample preparation.

Thermally reversible hydrogels printing of customizable bio-channels with curvature

Replicating intricate bio-channels, akin to expansive vascular networks, offers numerous advantages including self-repair, replacing damaged bio-channels, testing drugs, and biomedical devices. But, crafting multi-sized, editable bio-channels with specific curvatures, particularly using natural polymer-based bio-inks, poses a significant challenge. To address this, this study introduces a temperature-driven indirect printing method, exemplified by the diploic vein. Here, K-carrageenan (kca)-silk fiber (SF)-hyaluronic acid (HA)/hFOB 1.19 (SV40 transfection of human osteoblasts) and kca-collagen-HA/HUVECs (human umbilical vein endothelial cells) are employed to fabricate vascular-like walls and lumens, utilizing their thermoreversible properties to create multi-stage bifurcated lumens. Precise spatial curvature was generated by heating the vascular network wrapped in poly(N-isopropyl acrylamide) (PNIPAAm)-poly(ethylene glycol) diacrylate (PEGDA). Since temperature is specific to the thermal material carrying the cells, the rheological properties of bioinks, modeling temperature parameters, and their impact on printing size was explored. Additionally, mechanical properties and curvature response were characterized to determine the necessary process parameters for achieving the desired size. Ultimately, in vitro bioprinting experiments involving HUVECs and hFOB 1.19 demonstrate cell viability, adhesion, proliferation, and migration within the intraluminal hydrogel scaffold. This approach allows for customizing bio-channel content and controlling curvature programming, providing new prospects for in vitro biochannel production, with potential benefits for pathology research.

3D printed porous membrane integrated devices to study the chemoattractant induced behavioural response of aquatic organisms

Biological models with genetic similarities to humans are used for exploratory research to develop behavioral screening tools and understand sensory-motor interactions. Their small, often mm-sized appearance raises challenges in the straightforward quantification of their subtle behavioral responses and calls for new, customisable research tools. 3D printing provides an attractive approach for the manufacture of custom designs at low cost; however, challenges remain in the integration of functional materials like porous membranes. Nanoporous membranes have been integrated with resin exchange using purpose-designed resins by digital light projection 3D printing to yield functionally integrated devices using a simple, economical and semi-automated process. Here, the impact of the layer thickness and layer number on the porous properties - parameters unique for 3D printing - are investigated, showing decreases in mean pore diameter and porosity with increasing layer height and layer number. From the same resin formulation, materials with average pore size between 200 and 600 nm and porosity between 45% and 61% were printed. Membrane-integrated devices were used to study the chemoattractant induced behavioural response of zebrafish embryos and planarians, both demonstrating a predominant behavioral response towards the chemoattractant, spending >85% of experiment time in the attractant side of the observation chamber. The presented 3D printing method can be used for printing custom designed membrane-integrated devices using affordable 3D printers and enable fine-tuning of porous properties through adjustment of layer height and number. This accessible approach is expected to be adopted for applications including behavioural studies, early-stage pre-clinical drug discovery and (environmental) toxicology.

Potential Applications and Additive Manufacturing Technology-Based Considerations of Mesoporous Silica: A Review

Nanoporous materials are categorized as microporous (pore sizes 0.2-2 nm), mesoporous (pore sizes 2-50 nm), and macroporous (pore sizes 50-1000 nm). Mesoporous silica (MS) has gained a significant interest due to its notable characteristics, including organized pore networks, specific surface areas, and the ability to be integrated in a variety of morphologies. Recently, MS has been widely accepted by range of manufacturer and as drug carrier. Moreover, silica nanoparticles containing mesopores, also known as mesoporous silica nanoparticles (MSNs), have attracted widespread attention in additive manufacturing (AM). AM commonly known as three-dimensional printing is the formalized rapid prototyping (RP) technology. AM techniques, in comparison to conventional methods, aid in reducing the necessity for tooling and allow versatility in product and design customization. There are generally several types of AM processes reported including VAT polymerization (VP), powder bed fusion (PBF), sheet lamination (SL), material extrusion (ME), binder jetting (BJ), direct energy deposition (DED), and material jetting (MJ). Furthermore, AM techniques are utilized in fabrication of various classified fields such as architectural modeling, fuel cell manufacturing, lightweight machines, medical, and fabrication of drug delivery systems. The review concisely elaborates on applications of mesoporous silica as versatile material in fabrication of various AM-based pharmaceutical products with an elaboration on various AM techniques to reduce the knowledge gap.

Vat photopolymerization 3D printed microfluidic devices for organ-on-a-chip applications

Organs-on-a-chip, or OoCs, are microfluidic tissue culture devices with micro-scaled architectures that repeatedly achieve biomimicry of biological phenomena. They are well positioned to become the primary pre-clinical testing modality as they possess high translational value. Current methods of fabrication have facilitated the development of many custom OoCs that have generated promising results. However, the reliance on microfabrication and soft lithographic fabrication techniques has limited their prototyping turnover rate and scalability. Additive manufacturing, known commonly as 3D printing, shows promise to expedite this prototyping process, while also making fabrication easier and more reproducible. We briefly introduce common 3D printing modalities before identifying two sub-types of vat photopolymerization - stereolithography (SLA) and digital light processing (DLP) - as the most advantageous fabrication methods for the future of OoC development. We then outline the motivations for shifting to 3D printing, the requirements for 3D printed OoCs to be competitive with the current state of the art, and several considerations for achieving successful 3D printed OoC devices touching on design and fabrication techniques, including a survey of commercial and custom 3D printers and resins. In all, we aim to form a guide for the end-user to facilitate the in-house generation of 3D printed OoCs, along with the future translation of these important devices.

Rapid prototyping of microfluidic chips enabling controlled biotechnology applications in microspace

Rapid prototyping of microfluidic chips is a key enabler for controlled biotechnology applications in microspaces, as it allows for the efficient design and production of microfluidic systems. With rapid prototyping, researchers and engineers can quickly create and test new microfluidic chip designs, which can then be optimized for specific applications in biotechnology. One of the key advantages of microfluidic chips for biotechnology is the ability to manipulate and control biological samples in a microspace, which enables precise and controlled experiments under well-defined conditions. This is particularly useful for applications such as cell culture, drug discovery, and diagnostic assays, where precise control over the biological environment is crucial for obtaining accurate results. Established methods, for example, soft lithography, 3D printing, injection molding, as well as other recently highlighted innovative approaches, will be compared and challenges as well as limitations will be discussed. It will be shown that rapid prototyping of microfluidic chips enables the use of advanced materials and technologies, such as smart materials and digital sensors, which can further enhance the capabilities of microfluidic systems for biotechnology applications. Overall, rapid prototyping of microfluidic chips is an important enabling technology for controlled biotechnology applications in microspaces, as well as for upscaling it into macroscopic bioreactors, and its continued development and improvement will play a critical role in advancing the field. The review will highlight recent trends in terms of materials and competing approaches and shed light on current challenges on the way toward integrated microtechnologies. Also, the possibility to easy and direct implementation of novel functions (membranes, functionalization of interfaces, etc.) is discussed.

3D-printed chemiluminescence flow cells with customized cross-section geometry for enhanced analytical performance

Low force stereolithography is exploited for the first time for one-step facile fabrication of chemiluminescence (CL) flow-through cells that bear unrivalled features as compared to those available through milling or blowing procedures or alternative 3D printing technologies. A variety of bespoke cross-section geometries with polyhedral features (namely, triangular, square, and five-side polygon) as well as semicircular cross-section are herein critically evaluated in terms of analytical performance against the standardcircular cross-section in a flat spirally-shape format. The idea behind is to maximize capture of elicited light by the new designs while leveraging 3D printing further for fabrication of (i) customized gaskets that enable reliable attaching of the active mixing zone of the CL cell to the detection window, (ii) in-line 3D-printed serpentine reactors, and (iii) flow confluences with tailorable shapes for enhancing mixing of samples with CL reagents. Up to twenty transparent functional cells were simultaneously fabricated without inner supports following post-curing and surface treatment protocols lasting less than 5 h. In fact, previous attempts to print spirally-shaped cells in one-step by resorting to less cost effective photopolymer inkjet printing technologies were unsuccessful because of the requirement of lengthy procedures (>15 days) for quantitative removal of the support material. By exploiting the phthalazinedione-hydrogen peroxide chemistry as a model reaction, the five-side irregular pentagon cell exhibited superior analytical figures of merit in terms of LOD, dynamic range and intermediate precision as compared to alternative designs. Computational fluid dynamic simulations for mapping velocities at the entry region of the spiral cell corroborated the fact that the 5-side polygon cross-section flow-cell with Y-type confluence permitted the most efficient mixing of reagents and sample while enabling larger flow velocities near the inlet that contribute to a more efficient capture of the photons from the flash-type reaction. The applicability of the 3D-printed 5-side polygon CL cell for automatic determination of hydrogen peroxide using a computerized hybrid flow system was demonstrated for the analysis of high matrix samples, viz., seawater and saliva, with relative recoveries ranging from 83 to 103%.

Digital manufacturing for accelerating organ-on-a-chip dissemination and electrochemical biosensing integration

Organ on-a-chip (OoC) is a promising technology that aims to recapitulate human body pathophysiology in a more precise way to advance in drug development and complex disease understanding. However, the presence of OoC in biological laboratories is still limited and mainly restricted to laboratories with access to cleanroom facilities. Besides, the current analytical methods employed to extract information from the organ models are endpoint and post facto assays which makes it difficult to ensure that during the biological experiment the cell microenvironment, cellular functionality and behaviour are controlled. Hence, the integration of real-time biosensors is highly needed and requested by the OoC end-user community to provide insight into organ function and responses to stimuli. In this context, electrochemical sensors stand out due to their advantageous features like miniaturization capabilities, ease of use, automatization and high sensitivity and selectivity. Electrochemical sensors have been already successfully miniaturized and employed in other fields such as wearables and point-of-care devices. We have identified that the explanation for this issue may be, to a large extent, the accessibility to microfabrication technologies. These fields employ preferably digital manufacturing (DM), which is a more accessible microfabrication approach regardless of funding and facilities. Therefore, we envision that a paradigm shift in microfabrication that adopts DM instead of the dominating soft lithography for the in-lab microfabrication of OoC devices will contribute to the dissemination of the field and integration of the promising real-time sensing.

Application of Microfluidic Chips in the Detection of Airborne Microorganisms

The spread of microorganisms in the air, especially pathogenic microorganisms, seriously affects people's normal life. Therefore, the analysis and detection of airborne microorganisms is of great importance in environmental detection, disease prevention and biosafety. As an emerging technology with the advantages of integration, miniaturization and high efficiency, microfluidic chips are widely used in the detection of microorganisms in the environment, bringing development vitality to the detection of airborne microorganisms, and they have become a research highlight in the prevention and control of infectious diseases. Microfluidic chips can be used for the detection and analysis of bacteria, viruses and fungi in the air, mainly for the detection of Escherichia coli, Staphylococcus aureus, H1N1 virus, SARS-CoV-2 virus, Aspergillus niger, etc. The high sensitivity has great potential in practical detection. Here, we summarize the advances in the collection and detection of airborne microorganisms by microfluidic chips. The challenges and trends for the detection of airborne microorganisms by microfluidic chips was also discussed. These will support the role of microfluidic chips in the prevention and control of air pollution and major outbreaks.

Peak broadening caused by using different micro-liquid chromatography detectors

Advancements in column technology resulted in smaller particles and more efficient phases. In parallel, the use of columns with reduced dimensions is becoming more common. This means the effective column volume is also decreased, thereby making the systems more susceptible to effects of band broadening due to extra-column volume. Despite these trends and the fact that a growing number of miniaturized liquid chromatography systems are being offered commercially, manufacturers often stick to the modular concept with dedicated units for pumps, column oven, and detectors. This modular design results in long connection capillaries, which leads to extra-column band broadening and consequently prevents the exploitation of the intrinsic efficiency of state-of-the-art columns. In particular, band broadening post column has a considerable negative effect on efficiency. In this study, mass flow and concentration-dependent detectors were examined for their influence on band broadening using a micro-LC system. A mass spectrometric detector, an evaporative light scattering detector, two UV detectors, and a previously undescribed fluorescence detector were compared. The influence on efficiency is compared using plate height vs linear velocity data and peak variance. It is shown that an increase in the inner diameter after the post-column transfer capillary leads to significant loss in plate height. Comparing the UV detectors, it could be shown that the dispersion was reduced by 38% by the reduction of the post-column volume. The largest variance was found for the evaporative light scattering detector, which was 368% higher compared to the variance of the detector with the least effect on band broadening.

Plasmonic photoreactors-coated plastic tubing as combined-active-and-passive antimicrobial flow sterilizer

Plastic materials are ubiquitous in medical devices and consumer goods. As bacterial contamination of plastic surfaces can pose significant health risks, there is a need for effective approaches both to inactivate bacteria on plastic surfaces and to prevent colonization of plastic surfaces. In this study, we evaluate a plasmonic photoreactor coating for plastic surfaces that provides both active and passive antimicrobial effects and implement a visible light-driven antibacterial flow sterilizer. We demonstrate that this approach inactivates bacteria in an aqueous suspension passed through a photoreactor-coated polyethylene tubing, achieving log reduction values (LRVs) > 5 for both Gram-positive and -negative bacteria under resonant LED illumination. Importantly, the antimicrobial flow sterilizers do not cause a detectable loss of functionality for monoclonal antibodies that were included in this work as an example of high-value biologics that require sterilization. Under ambient light illumination, the plasmonic photoreactor coating exhibits a significant inhibitory effect on bacterial colonization and biofilm formation. The inhibitory effect was substantially weaker for mammalian cells, indicating some selectivity in the protection provided by the coating.

Microelectromechanical Systems Based on Magnetic Polymer Films

Microelectromechanical systems (MEMS) have been increasingly used worldwide in a wide range of applications, including high tech, energy, medicine or environmental applications. Magnetic polymer composite films have been used extensively in the development of the micropumps and valves, which are critical components of the microelectromechanical systems. Based on the literature survey, several polymers and magnetic micro and nanopowders can be identified and, depending on their nature, ratio, processing route and the design of the device, their performances can be tuned from simple valves and pumps to biomimetic devices, such as, for instance, hearth ventricles. In many such devices, polymer magnetic films are used, the disposal of the magnetic component being either embedded into the polymer or coated on the polymer. One or more actuation zones can be used and the flow rate can be mono-directional or bi-directional depending on the design. In this paper, we review the main advances in the development of these magnetic polymer films and derived MEMS: microvalve, micropump, micromixer, microsensor, drug delivery micro-systems, magnetic labeling and separation microsystems, etc. It is important to mention that these MEMS are continuously improving from the point of view of performances, energy consumption and actuation mechanism and a clear tendency in developing personalized treatment. Due to the improved energy efficiency of special materials, wearable devices are developed and be suitable for medical applications.