Automated melt electrowritting platform with real-time process monitoring

Enhancing compliance and extracellular matrix properties of tissue-engineered vascular grafts through pulsatile bioreactor culture

Biofabrication techniques represent a promising avenue for the production of small diameter vascular grafts. However, while current tissue-engineered vascular grafts (TEVGs) fulfil certain functional requirements of native blood vessels, most exhibit very poor mechanical compliance, directly reducing patency in vivo. Here, highly compliant TEVGs were cultured in a dynamic pulsatile bioreactor which ensured enhanced compliance, using biomimetic melt electrowritten (MEW) tubular scaffolds as substrates for tissue growth. Through 6-week in vitro culture, we investigated differences in extracellular matrix (ECM) production and mechanical performance of TEVGs cultured with placental mesenchymal stem cells (MSCs) and smooth muscle cells (SMCs) in static and dynamic conditions. Pulsatile stimulation successfully maintained the high compliance (12.4 ± 0.8 % per 100 mmHg) of our biomimetic scaffolds, substantially greater than existing small diameter grafts. Dynamic TEVGs demonstrated physiologically relevant burst pressure (1125 ± 212 mmHg) and suture pull-out force (3.0 ± 0.4 N), while also accumulating greater ECM components than static TEVGs. To assess off-the-shelf suitability, grafts were decellularized and lyophilised to produce d-TEVGs, which exhibited negligible loss of mechanics or ECM integrity. Finally, rehydrated d-TEVGs were seeded with endothelial cells in vitro, with an intimal endothelial lining forming after 7 days. These findings demonstrate the production of TEVGs with specifically engineered mechanical compliance which has been maintained by dynamic in vitro culture, supporting continued work toward biofabrication of the next generation of vascular grafts.

Redesigning FDM Platforms for Bio-Printing Applications

Fused Deposition Modeling (FDM) is a prominent additive manufacturing technique known for its ability to provide cost-effective and fast printing solutions. FDM enables the production of computer-aided 3D designs as solid objects at macro scales with high-precision alignment while sacrificing excellent surface smoothness compared to other 3D printing techniques such as SLA (Stereolithography) and SLS (Selective Laser Sintering). Electro-Spinning (ES) is another technique for producing soft-structured nonwoven micro-scale materials, such as nanofibers. However, compared to the FDM technique, it has limited accuracy and sensitivity regarding high-precision alignment. The need for high-precision alignment of micro-scaled soft structures during the printing process raises the question of whether FDM and ES techniques can be combined. Today, the printing technique with such capability is called Melt Electro Writing (MEW), and in practice, it refers to the basic working principle on which bio-printers are based. This paper aims to examine how these two techniques can be combined affordably. Comparatively, it presents output production processes, design components, parameters, and materials used in output production. It discusses the limitations and advantages of such a hybrid platform, specifically from the perspective of engineering design and its biomedical applications.

Towards industry-ready additive manufacturing: AI-enabled closed-loop control for 3D melt electrowriting

Melt electrowriting (MEW) is an emerging high-resolution 3D printing technology used in biomedical engineering, regenerative medicine, and soft robotics. Its transition from academia to industry faces challenges such as slow experimentation, low printing throughput, poor reproducibility, and user-dependent operation, largely due to the nonlinear and multiparametric nature of the MEW process. To address these challenges, we applied computer vision and machine learning to monitor and analyze the process in real-time through imaging of the MEW jet between the nozzle-collector gap. To collect data for training we developed an automated data collection methodology that eases the experimental time from days to hours. A feedforward neural network, working in concert with optimization methods and a feedback loop, is used to develop closed-loop control ensuring reproducibility of the printed parts. We demonstrate that machine learning allows streamlining the MEW operation via closed-loop control of the highly nonlinear 3D printing technology.

Advances in melt electrowriting for cardiovascular applications

Melt electrowriting (MEW) is an electric-field-assisted additive biofabrication technique that has brought significant advancements to bioinspired scaffold design for soft tissue engineering and beyond. Owing to its targeted microfiber placement, MEW has become a powerful platform technology for the fabrication of in vitro disease models up to functional biohybrid constructs that are investigated in vivo to reach clinical translation soon. This work provides a concise overview of this rapidly evolving field by highlighting the key contributions of MEW to cardiovascular tissue engineering. Specifically, we i) pinpoint the methods to introduce microvascular networks in thick 3D constructs benefitting from (sacrificial) MEW microfibers, ii) report MEW-based concepts for small-diameter vascular grafts and stents, iii) showcase how contracting cardiac tissues can profit from the tunable structure-property relationship of MEW scaffolds, and iv) address how complete regenerative heart valves can be built on complex fiber scaffold architectures that recapitulate J-shaped tensile properties and tissue heterogeneity. Lastly, we touch on novel biomaterial advancements and discuss the technological challenges of MEW to unlock the full potential of this transformative technology.

Materials and Strategies to Enhance Melt Electrowriting Potential

Melt electrowriting (MEW) is an emerging additive manufacturing (AM) technology that enables the precise deposition of continuous polymeric microfibers, allowing for the creation of high-resolution constructs. In recent years, MEW has undergone a revolution, with the introduction of active properties or additional functionalities through novel polymer processing strategies, the incorporation of functional fillers, postprocessing, or the combination with other techniques. While extensively explored in biomedical applications, MEW's potential in other fields remains untapped. Thus, this review explores MEW's characteristics from a materials science perspective, emphasizing the diverse range of materials and composites processed by this technique and their current and potential applications. Additionally, the prospects offered by postprinting processing techniques are explored, together with the synergy achieved by combining melt electrowriting with other manufacturing methods. By highlighting the untapped potentials of MEW, this review aims to inspire research groups across various fields to leverage this technology for innovative endeavors.

Filament-Based Melt Electrowriting Enables Dual-Mode Additive Manufacturing for Multiscale Constructs

Melt electrowriting (MEW) is an electric-field-assisted fiber-forming biofabrication strategy for the additive manufacturing (AM) of precisely defined 3D microarchitectures. MEW is based on pressure-driven extrusion of a polymer melt pool, currently mainly implemented at laboratory scale with specialized machine technology and limited to only few materials. This precludes the accessibility of MEW to a broader user group and can become the bottleneck of MEW's technological advancement. In contrast to conventional MEW, a filament-based approach (F-MEW) is introduced that exploits the technological ecosystem of fused filament fabrication (FFF), a globally used transformative AM technique. In this work, a polymer filament serves as feedstock material and is melted just on demand. By upgrading existing FFF systems, MEW of polymer microfibers is enabled, as validated with polycaprolactone (PCL) and demonstrated with direct writing of thermosensitive polydioxanone (PDO). Finally, FFF and F-MEW are hybridized in a dual-mode AM process. This enables multiscale constructs featuring both FFF struts and one order of magnitude smaller F-MEW microfibers. This work opens the accessibility of F-MEW to the large FFF user group, potentially benefitting from the plethora of filaments available for FFF, while, at the same time, expanding the FFF fabrication window.