Suppression of Filament Defects in Embedded 3D Printing

3D Bioprinting of Liquid High-Cell-Proportion Bioinks in Liquid Granular Bath

Embedded 3D bioprinting techniques have emerged as a powerful method to fabricate 3D engineered constructs using low strength bioinks; however, there are challenges in simultaneously satisfying the requirements of high-cell-activity, high-cell-proportion, and low-viscosity bioinks. In particular, the printing capacity of embedded 3D bioprinting is limited as two main challenges: spreading and diffusion, especially for liquid, high-cell-activity bioinks that can facilitate high-cell-proportion. Here, a liquid-in-liquid 3D bioprinting (LL3DBP) strategy is developed, which used a liquid granular bath to prevent the spreading of liquid bioinks during 3D printing, and electrostatic interaction between the liquid bioinks and liquid granular baths is found to effectively prevent the diffusion of liquid bioinks. As an example, the printing of positively charged 5% w/v gelatin methacryloyl (GelMA) in a liquid granular bath prepared with negatively charged κ-carrageenan is proved to be achievable. By LL3DBP, printing capacity is greatly advanced and bioinks with over 90% v/v cell can be printed, and printed structures with high-cell-proportion exhibit excellent bioactivity.

All-Aqueous Embedded 3D Printing for Freeform Fabrication of Biomimetic 3D Constructs

All-aqueous embedded 3D printing, which involves extruding inks in an aqueous bath, has emerged as a transformative platform for the freeform fabrication of 3D constructs with precise control. The use of a supporting bath not only enables the printing of arbitrarily designed 3D constructs but also broadens ink selection for various soft matters, advancing the wide application of this technology. This review focuses on recent progress in the freeform preparation of 3D constructs using all-aqueous embedded 3D printing. It begins by discussing the significance of ultralow interfacial tension in all-liquid embedded printing and highlights the fundamental concepts and properties of all-aqueous system. The review then introduces recent advances in all-aqueous embedded 3D printing and clarifies the key factors affecting printing stability and shape fidelity, aiming to guide expansion and assessment of emerging printing systems used for various representative applications. Furthermore, it proposes the potential scope and applications of this technology, including in vitro models, cytomimetic microreactors, and soft ionic electronics. Finally, the review discusses the challenges facing current all-aqueous embedded 3D printing and offers future perspectives on possible improvements and developments.

Embedded 3D Printing for Microchannel Fabrication in Epoxy-Based Microfluidic Devices

Microfluidic devices offer promising solutions for automating various biological and chemical procedures. Epoxy resin, known for its excellent mechanical properties, chemical resistance, and thermal stability, is widely used in high-performance microfluidic devices. However, the poor printability of epoxy has limited its application in 3D printing technologies for fabricating epoxy-based microfluidic devices. In this study, fumed silica is introduced into epoxy resin to formulate a yield-stress fluid suspension as a support bath for embedded 3D printing (e-3DP). The study demonstrates that increasing the fumed silica concentration from 3.0% to 9.0% (w/v) enhances the yield stress from 9.46 Pa to 56.41 Pa, the compressive modulus from 19.79 MPa to 36.34 MPa, and the fracture strength from 148.16 MPa to 168.78 MPa, while reducing the thixotropic time from 6.58 s to 1.32 s, albeit with a 61.3% decrease in the transparency ratio. The 6.0% (w/v) fumed silica-epoxy suspension is selected based on a balance between yield stress, transparency, and mechanical performance, enabling high-fidelity filament formation. Two representative microfluidic devices are successfully fabricated, demonstrating the feasibility of a fumed silica-epoxy suspension for the customizable e-3DP of epoxy-based microfluidic devices.

Simulated inter-filament fusion in embedded 3D printing

In embedded 3D printing (EMB3D), a nozzle extrudes continuous filaments inside of a viscoelastic support bath. Compared to other extrusion processes, EMB3D enables softer structures and print paths that conform better to the shape of the part, allowing for complex structures such as tissues and organs. However, strategies for high-quality dimensional accuracy and mechanical properties remain undocumented in EMB3D. This work uses computational fluid dynamics simulations in OpenFOAM to probe the underlying physics behind two processes: deformation of the printed part due to nearby nozzle motion and fusion between neighboring filaments during printing. Through simulations, we disentangle yielding from viscous dissipation, and we isolate interfacial tension effects from rheology effects, which are difficult to separate in experiments. Critically, these simulations find that disturbance and fusion are controlled by the flow of support fluid around the nozzle. To avoid part deformation, the nozzle must remain far from existing parts during non-printing moves, moreso when traveling next to the part than above the part and especially when the interfacial tension between the ink and support is non-zero. Additionally, because support can become trapped between filaments at zero interfacial tension, the spacing between filaments must be tight enough to produce over-printing, or printing too much material for the designed space. In non-Newtonian fluids, spacings for vertical walls must be even tighter than spacings for horizontal planes. At these spacings, printing a new filament sometimes creates and sometimes mitigates shape defects in the old filament. While non-zero ink-support interfacial tensions produce better inter-filament fusion than zero interfacial tension, interfacial tension also produces shape defects. Slicing algorithms that consider these unique EMB3D defects are needed to improve mechanical properties and dimensional accuracy of bioprinted constructs.

Filament Disturbance and Fusion during Embedded 3D Printing of Silicones

Embedded 3D printing (EMB3D) is an additive manufacturing technique that enables complex fabrication of soft materials including tissues and silicones. In EMB3D, a nozzle writes continuous filaments into a support bath consisting of a yield stress fluid. Lack of fusion defects between filaments can occur because the nozzle pushes support fluid into existing filaments, preventing coalescence. Interfacial tension was previously proposed as a tool to drive interfilament fusion. However, interfacial tension can also drive rupture and shrinkage of printed filaments. Here, we evaluate the efficacy of interfacial tension as a tool to control defects in EMB3D. Using polydimethylsiloxane (PDMS)-based inks with varying amounts of fumed silica and surfactant, printed into Laponite in water supports, we evaluate the effect of rheology, interfacial tension, print speeds, and interfilament spacings on defects. We print pairs of parallel filaments at varying orientations in the bath and use digital image analysis to quantify shrinkage, rupture, fusion, and positioning defects. By comparing disturbed filaments to printed pairs of filaments, we disentangle the effects of nozzle movement and filament extrusion. Critically, we find that capillary instabilities and interfilament fusion scale with the balance between support rheology and interfacial tension. Less viscous supports and higher interfacial tensions lead to more shrinkage and rupture at all points in the printing process, from relaxation after writing, to disturbance of the line, to writing of a second line. It is necessary to overextrude material to achieve interfilament fusion, particularly at high support viscosities and low interfacial tensions. Finally, fusion quality varies with printing orientation, and writing neighboring filaments causes displacement of existing structures. As such, specialized slicers are needed for EMB3D that consider the tighter spacings and orientation-dependent spacings necessary to achieve precise control over printed shapes.

Embedded 3D Bioprinting of Collagen Inks into Microgel Baths to Control Hydrogel Microstructure and Cell Spreading

Microextrusion-based 3D bioprinting into support baths has emerged as a promising technique to pattern soft biomaterials into complex, macroscopic structures. It is hypothesized that interactions between inks and support baths, which are often composed of granular microgels, can be modulated to control the microscopic structure within these macroscopic-printed constructs. Using printed collagen bioinks crosslinked either through physical self-assembly or bioorthogonal covalent chemistry, it is demonstrated that microscopic porosity is introduced into collagen inks printed into microgel support baths but not bulk gel support baths. The overall porosity is governed by the ratio between the ink's shear viscosity and the microgel support bath's zero-shear viscosity. By adjusting the flow rate during extrusion, the ink's shear viscosity is modulated, thus controlling the extent of microscopic porosity independent of the ink composition. For covalently crosslinked collagen, printing into support baths comprised of gelatin microgels (15-50 µm) results in large pores (≈40 µm) that allow human corneal mesenchymal stromal cells (MSCs) to readily spread, while control samples of cast collagen or collagen printed in non-granular support baths do not allow cell spreading. Taken together, these data demonstrate a new method to impart controlled microscale porosity into 3D printed hydrogels using granular microgel support baths.

Simultaneous rheology and cure kinetics dictate thermal post-curing of thermoset composite resins for material extrusion

Thermoset composites are excellent candidates for material extrusion because they shear thin during extrusion but retain their shape once deposited via a yield stress. However, thermal post-curing is often required to solidify these materials, which can destabilize printed parts. Elevated temperatures can decrease the rheological properties responsible for stabilizing the printed structure before crosslinking solidifies the material. These properties, namely the storage modulus and yield stress, must therefore be characterized as a function of temperature and extent of reaction for various filler loadings. This work utilizes rheo-Raman spectroscopy to measure the storage modulus and dynamic yield stress as a function of temperature and conversion in epoxy-amine resins with fumed silica mass fractions up to 10 %. Both rheological properties are sensitive to conversion and particle loading, but only the dynamic yield stress is reduced by elevated temperatures early in the cure. Notably, the dynamic yield stress increases with conversion well before the chemical gel point. These findings motivate a two-step cure protocol that starts at a low temperature to mitigate the drop in dynamic yield stress, then ramps up to a high temperature when the dynamic yield stress is no longer at risk of decreasing to rapidly drive conversion to near completion. The results suggests that structural stability can be improved without resorting to increasing filler content, which limits control over the final properties, laying the groundwork for future studies to evaluate the stability improvements provided by the multi-step curing schedules.

The current state of the art in gellan-based printing inks in tissue engineering

With the advancement of enhanced fabrication technologies, specifically 3D printing, it is now possible to build artificial tissue for personalized healing. However, inks developed from polymers often fail to meet expectations in terms of mechanical strength, scaffold integrity, and the stimulation of tissue formation. Developing new printable formulations as well as adapting existing printing methods is an essential aspect of contemporary biofabrication research. In order to push the boundaries of the printability window, various strategies have been developed employing gellan gum. This has resulted in major breakthroughs in the development of 3D hydrogels scaffolds that exhibit significant resemblance to genuine tissues and enables the fabrication of more complex systems. In light of the many uses of gellan gum, the purpose of this paper is to provide a synopsis of the printable ink designs drawing attention to the various compositions and fabrication approaches that may be used for tuning the properties of 3D printed hydrogels for tissue engineering applications. The purpose of this article is to outline the development of gellan-based 3D printing inks and to encourage research by highlighting the possible applications of gellan gum.

Associative Liquid-In-Liquid 3D Printing Techniques for Freeform Fabrication of Soft Matter

Shaping soft materials into prescribed 3D complex designs has been challenging yet feasible using various 3D printing technologies. For a broader range of soft matters to be printable, liquid-in-liquid 3D printing techniques have emerged in which an ink phase is printed into 3D constructs within a bath. Most of the attention in this field has been focused on using a support bath with favorable rheology (i.e., shear-thinning behavior) which limits the selection of materials, impeding the broad application of such techniques. However, a growing body of work has begun to leverage the interaction or association of the two involved phases (specifically at the liquid-liquid interface) to fabricate complex constructs from a myriad of soft materials with practical structural, mechanical, optical, magnetic, and communicative properties. This review article has provided an overview of the studies on such associative liquid-in-liquid 3D printing techniques along with their fundamentals, underlying mechanisms, various characterization techniques used for ensuring the structural stability, and practical properties of prints. Also, the future paths with the potential applications are discussed.

Embedded 3D Printing of Multimaterial Polymer Lattices via Graph-Based Print Path Planning

Recent advances in computational design and 3D printing enable the fabrication of polymer lattices with high strength-to-weight ratio and tailored mechanics. To date, 3D lattices composed of monolithic materials have primarily been constructed due to limitations associated with most commercial 3D printing platforms. Here, freeform fabrication of multi-material polymer lattices via embedded three-dimensional (EMB3D) printing is demonstrated. An algorithm is developed first that generates print paths for each target lattice based on graph theory. The effects of ink rheology on filamentary printing and the effects of the print path on resultant mechanical properties are then investigated. By co-printing multiple materials with different mechanical properties, a broad range of periodic and stochastic lattices with tailored mechanical responses can be realized opening new avenues for constructing architected matter.

3D Printed Silicones with Shape Morphing and Low-Temperature Ultraelasticity

3D printed silicones have demonstrated great potential in diverse areas by combining the advantageous physiochemical properties of silicones with the unparalleled design freedom of additive manufacturing. However, their low-temperature performance, which is of particular importance for polar and space applications, has not been addressed. Herein, a 3D printed silicone foam with unprecedented low-temperature elasticity is presented, which is featured with extraordinary fatigue resistance, excellent shape recovery, and energy-absorbing capability down to a low temperature of -60 °C after extreme compression (an intensive load of over 66000 times its own weight). The foam is achieved by direct writing of a phenyl silicone-based pseudoplastic ink embedded with sodium chloride as sacrificial template. During the water immersion process to create pores in the printed filaments, a unique osmotic pressure-driven shape morphing strategy is also reported, which offers an attractive alternative to traditional 4D printed hydrogels in virtue of the favorable mechanical robustness of the silicone material. The underlying mechanisms for shape morphing and low-temperature elasticity are discussed in detail.