Printing of Hydrophobic Materials in Fumed Silica Nanoparticle Suspension

High-Speed Embedded Ink Writing of Anatomic-Size Organ Constructs

Embedded ink writing (EIW) is an emerging 3D printing technique that fabricates complex 3D structures from various biomaterial inks but is limited to a printing speed of ∼10 mm s-1 due to suboptimal rheological properties of particulate-dominated yield-stress fluids when used as liquid baths. In this work, a particle-hydrogel interactive system to design advanced baths with enhanced yield stress and extended thixotropic response time for realizing high-speed EIW is developed. In this system, the interactions between particle additive and three representative polymeric hydrogels enable the resulting nanocomposites to demonstrate different rheological behaviors. Accordingly, the interaction models for the nanocomposites are established, which are subsequently validated by macroscale rheological measurements and advanced microstructure characterization techniques. Filament formation mechanisms in the particle-hydrogel interactive baths are comprehensively investigated at high printing speeds. To demonstrate the effectiveness of the proposed high-speed EIW method, an anatomic-size human kidney construct is successfully printed at 110 mm s-1, which only takes ∼4 h. This work breaks the printing speed barrier in current EIW and propels the maximum printing speed by at least 10 times, providing an efficient and promising solution for organ reconstruction in the future.

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.

3D Printing of Metals with sub-10 µm Resolution

The ability to manufacture 3D metallic architectures with microscale resolution is greatly pursued because of their diverse applications in microelectromechanical systems (MEMS) including microelectronics, mechanical metamaterials, and biomedical devices. However, the well-developed photolithography and emerging metal additive manufacturing technologies have limited abilities in manufacturing micro-scaled metallic structures with freeform 3D geometries. Here, for the first time, the high-fidelity fabrication of arbitrary metallic motifs with sub-10 µm resolution is achieved by employing an embedded-writing embedded-sintering (EWES) process. A paraffin wax-based supporting matrix with high thermal stability is developed, which permits the printed silver nanoparticle ink to be pre-sintered at 175 °C to form metallic green bodies. Via carefully regulating the matrix components, the printing resolution is tuned down to ≈7 µm. The green bodies are then embedded in a supporting salt bath and further sintered to realize freeform 3D silver motifs with great structure fidelity. 3D printing of various micro-scaled silver architectures is demonstrated such as micro-spring arrays, BCC lattices, horn antenna, and rotatable windmills. This method can be extended to the high-fidelity 3D printing of other metals and metal oxides which require high-temperature sintering, providing the pathways toward the design and fabrication of 3D MEMS with complex geometries and functions.

Dissecting the Interplay Mechanism among Process Parameters toward the Biofabrication of High-Quality Shapes in Embedded Bioprinting

Embedded bioprinting overcomes the barriers associated with the conventional extrusion-based bioprinting process as it enables the direct deposition of bioinks in 3D inside a support bath by providing in situ self-support for deposited bioinks during bioprinting to prevent their collapse and deformation. Embedded bioprinting improves the shape quality of bioprinted constructs made up of soft materials and low-viscosity bioinks, leading to a promising strategy for better anatomical mimicry of tissues or organs. Herein, the interplay mechanism among the printing process parameters toward improved shape quality is critically reviewed. The impact of material properties of the support bath and bioink, printing conditions, cross-linking mechanisms, and post-printing treatment methods, on the printing fidelity, stability, and resolution of the structures is meticulously dissected and thoroughly discussed. Further, the potential scope and applications of this technology in the fields of bioprinting and regenerative medicine are presented. Finally, outstanding challenges and opportunities of embedded bioprinting as well as its promise for fabricating functional solid organs in the future are discussed.

Investigation of the 3D Printing Process Utilizing a Heterophase System

Direct ink writing (DIW) requires careful selection of ink composition with specific rheological properties, and it has limitations, such as the inability to create overhanging parts or branched geometries. This study presents an investigation into enhancing the 3D printing process through the use of a heterophase system, aiming to overcome these limitations. A modification was carried out in the 3D printer construction, involving adjustments to the structural elements responsible for the extrusion device's movement. Additionally, a method for obtaining a heterophase system based on gelatin microparticles was developed to enable the 3D printing process with the upgraded printer. The structure and rheological properties of the heterophase system, varying in gelatin concentration, were thoroughly examined. The material's viscosity ranged from 5.4 to 32.8 kPa·s, exhibiting thixotropic properties, pseudoplastic behavior, and long-term stability at 20 °C. The developed 3D printing technology was successfully implemented using a heterophase system based on different gelatin concentrations. The highest product quality was achieved with a heterophase system consisting of 4.5 wt.% gelatin, which exhibited a viscosity of 22.4 kPa·s, enabling the production of products without spreading or compromising geometrical integrity.

Three-Dimensional Bioprinting of Naturally Derived Hydrogels for the Production of Biomimetic Living Tissues: Benefits and Challenges

Three-dimensional bioprinting is the process of manipulating cell-laden bioinks to fabricate living structures. Three-dimensional bioprinting techniques have brought considerable innovation in biomedicine, especially in the field of tissue engineering, allowing the production of 3D organ and tissue models for in vivo transplantation purposes or for in-depth and precise in vitro analyses. Naturally derived hydrogels, especially those obtained from the decellularization of biological tissues, are promising bioinks for 3D printing purposes, as they present the best biocompatibility characteristics. Despite this, many natural hydrogels do not possess the necessary mechanical properties to allow a simple and immediate application in the 3D printing process. In this review, we focus on the bioactive and mechanical characteristics that natural hydrogels may possess to allow efficient production of organs and tissues for biomedical applications, emphasizing the reinforcement techniques to improve their biomechanical properties.

Multimaterial Embedded 3D Printing of Composite Reinforced Soft Actuators

Soft pneumatic actuators (SPAs) have attracted enormous attention in the growing field of robotics. Among different SPAs, composite reinforced actuators (CRAs) are widely used because of their simple structure and high controllability. However, multistep molding, a time-consuming method, is still the predominant fabrication method. Here, we propose a multimaterial embedded printing method (ME3P) to fabricate CRAs. In comparison with other 3-dimensional printing methods, our method improves fabrication flexibility greatly. Via the design and fabrication of the reinforced composites' patterns and different geometries of the soft body, we demonstrate actuators with programmable responses (elongation, contraction, twisting, bending, and helical and omnidirectional bending). Finite element analysis is employed for the prediction of pneumatic responses and the inverse design of actuators based on specific actuation needs. Lastly, we use tube-crawling robots as a model system to demonstrate our ability to fabricate complex soft robots for practical applications. This work demonstrates the versatility of ME3P for the future manufacturing of CRA-based soft robots.

3D bioprinting and its innovative approach for biomedical applications

3D bioprinting or additive manufacturing is an emerging innovative technology revolutionizing the field of biomedical applications by combining engineering, manufacturing, art, education, and medicine. This process involved incorporating the cells with biocompatible materials to design the required tissue or organ model in situ for various in vivo applications. Conventional 3D printing is involved in constructing the model without incorporating any living components, thereby limiting its use in several recent biological applications. However, this uses additional biological complexities, including material choice, cell types, and their growth and differentiation factors. This state-of-the-art technology consciously summarizes different methods used in bioprinting and their importance and setbacks. It also elaborates on the concept of bioinks and their utility. Biomedical applications such as cancer therapy, tissue engineering, bone regeneration, and wound healing involving 3D printing have gained much attention in recent years. This article aims to provide a comprehensive review of all the aspects associated with 3D bioprinting, from material selection, technology, and fabrication to applications in the biomedical fields. Attempts have been made to highlight each element in detail, along with the associated available reports from recent literature. This review focuses on providing a single platform for cancer and tissue engineering applications associated with 3D bioprinting in the biomedical field.

Patterning Wettability for Open-Surface Fluidic Manipulation: Fundamentals and Applications

Effective manipulation of liquids on open surfaces without external energy input is indispensable for the advancement of point-of-care diagnostic devices. Open-surface microfluidics has the potential to benefit health care, especially in the developing world. This review highlights the prospects for harnessing capillary forces on surface-microfluidic platforms, chiefly by inducing smooth gradients or sharp steps of wettability on substrates, to elicit passive liquid transport and higher-order fluidic manipulations without off-the-chip energy sources. A broad spectrum of the recent progress in the emerging field of passive surface microfluidics is highlighted, and its promise for developing facile, low-cost, easy-to-operate microfluidic devices is discussed in light of recent applications, not only in the domain of biomedical microfluidics but also in the general areas of energy and water conservation.

Three-Dimensional Printing in Stimuli-Responsive Yield-Stress Fluid with an Interactive Dual Microstructure

Yield-stress support bath-enabled three-dimensional (3D) printing has been widely used in recent years for diverse applications. However, current yield-stress fluids usually possess single microstructures and still face the challenges of on-demand adding and/or removing support bath materials during printing, constraining their application scope. This study aims to propose a concept of stimuli-responsive yield-stress fluids with an interactive dual microstructure as support bath materials. The microstructure from a yield-stress additive allows the fluids to present switchable states at different stresses, facilitating an embedded 3D printing process. The microstructure from stimuli-responsive polymers enables the fluids to have regulable rheological properties upon external stimuli, making it feasible to perfuse additional yield-stress fluids during printing and easily remove residual fluids after printing. A nanoclay-Pluronic F127 nanocomposite is studied as a thermosensitive yield-stress fluid. The key material properties are characterized to unveil the interactions in the formed dual microstructure and microstructure evolutions at different stresses and temperatures. Core scientific issues, including the filament formation principle, surface roughness control, and thermal effects of the newly added nanocomposite, are comprehensively investigated. Finally, three representative 3D structures, the Hall of Prayer, capsule, and tube with changing diameter, are successfully printed to validate the printing capability of stimuli-responsive yield-stress fluids for fabricating arbitrary architectures.

Suppression of Filament Defects in Embedded 3D Printing

Embedded 3D printing enables the manufacture of soft, intricate structures. In the technique, a nozzle is embedded into a viscoelastic support bath and extrudes filaments or droplets. While embedded 3D printing expands the printable materials space to low-viscosity fluids, it also presents new challenges. Filament cross-sections can be tall and narrow, have sharp edges, and have rough surfaces. Filaments can also rupture or contract due to capillarity, harming print fidelity. Through digital image analysis of in situ videos of the printing process and images of filaments just after printing, we probe the effects of ink and support rheology, print speeds, and interfacial tension on defects in individual filaments. Using model materials, we determine that if both the ink and support are water-based, the local viscosity ratio near the nozzle controls the filament shape. If the ink is slightly more viscous than the support, a round, smooth filament is produced. If the ink is oil-based and the support is water-based, the capillary number, or the product of the ink speed and support viscosity divided by the interfacial tension, controls the filament shape. To suppress contraction and rupture, the capillary number should be high, even though this leads to trade-offs in roughness and roundness. Still, inks at nonzero interfacial tension can be advantageous, since they lead to much rounder and smoother filaments than inks at zero interfacial tension with equivalent viscosity ratios.

A hackable, multi-functional, and modular extrusion 3D printer for soft materials

Three-dimensional (3D) printing has emerged as a powerful tool for material, food, and life science research and development, where the technology’s democratization necessitates the advancement of open-source platforms. Herein, we developed a hackable, multi-functional, and modular extrusion 3D printer for soft materials, nicknamed Printer.HM. Multi-printhead modules are established based on a robotic arm for heterogeneous construct creation, where ink printability can be tuned by accessories such as heating and UV modules. Software associated with Printer.HM were designed to accept geometry inputs including computer-aided design models, coordinates, equations, and pictures, to create prints of distinct characteristics. Printer.HM could further perform versatile operations, such as liquid dispensing, non-planar printing, and pick-and-place of meso-objects. By ‘mix-and-match’ software and hardware settings, Printer.HM demonstrated printing of pH-responsive soft actuators, plant-based functional hydrogels, and organ macro-anatomical models. Integrating affordability and open design, Printer.HM is envisaged to democratize 3D printing for soft, biological, and sustainable material architectures.

Computational Modeling and Experimental Characterization of Extrusion Printing into Suspension Baths

The extrusion printing of inks into suspension baths is an exciting tool, as it allows the printing of diverse and soft hydrogel inks into 3D space without the need for layer-by-layer fabrication. However, this printing process is complex and there have been limited studies to experimentally and computationally characterize the process. In this work, hydrogel inks (i.e., gelatin methacrylamide (GelMA)), suspension baths (i.e., agarose, Carbopol), and the printing process are examined via rheological, computational, and experimental analyses. Rheological data on various hydrogel inks and suspension baths is utilized to develop computational printing simulations based on Carreau constitutive viscosity models of the printing of inks within suspension baths. These results are then compared to experimental outcomes using custom print designs where features such as needle translation speed, defined in this work as print speed, are varied and printed filament resolution is quantified. Results are then used to identify print parameters for the printing of a GelMA ink into a unique guest-host hyaluronic acid suspension bath. This work emphasizes the importance of key rheological properties and print parameters for suspension bath printing and provides a computational model and experimental tools that can be used to inform the selection of print settings.

Embedded bioprinting for designer 3D tissue constructs with complex structural organization

3D bioprinting has been developed as an effective and powerful technique for the fabrication of living tissue constructs in a well-controlled manner. However, most existing 3D bioprinting strategies face substantial challenges in replicating delicate and intricate tissue-specific structural organizations using mechanically weak biomaterials such as hydrogels. Embedded bioprinting is an emerging bioprinting strategy that can directly fabricate complex structures derived from soft biomaterials within a supporting matrix, which shows great promise in printing large vascularized tissues and organs. Here, we provide a state-of-the-art review on the development of embedded bioprinting including extrusion-based and light-based processes to manufacture complex tissue constructs with biomimetic architectures. The working principles, bioinks, and supporting matrices of embedded printing processes are introduced. The effect of key processing parameters on the printing resolution, shape fidelity, and biological functions of the printed tissue constructs are discussed. Recent innovations in the processes and applications of embedded bioprinting are highlighted, such as light-based volumetric bioprinting and printing of functional vascularized organ constructs. Challenges and future perspectives with regard to translating embedded bioprinting into an effective strategy for the fabrication of functional biological constructs with biomimetic structural organizations are finally discussed. STATEMENT OF SIGNIFICANCE: It is still challenging to replicate delicate and intricate tissue-specific structural organizations using mechanically-weak hydrogels for the fabrication of functional living tissue constructs. Embedded bioprinting is an emerging 3D printing strategy that enables to produce complex tissue structures directly inside a reservoir filled with supporting matrix, which largely widens the choice of bioprinting inks to ECM-like hydrogels. Here we aim to provide a comprehensive review on various embedded bioprinting techniques mainly including extrusion-based and light-based processes. Various bioinks, supporting matrices, key processing parameters as well as their effects on the structures and biological functions of resultant living tissue constructs are discussed. We expect that it can provide an important reference and generate new insights for the bioprinting of large vascularized tissues and organs with biological functions.

Freeform Liquid 3D Printing of Soft Functional Components for Soft Robotics

Freeform liquid three-dimensional printing (FL-3DP) is a promising new additive manufacturing process that uses a yield stress gel as a temporary support, enabling the processing of a broader class of inks into complex geometries, including those with low viscosities or long solidification kinetics that were previously not processable. However, the full exploitation of these advantages for the fabrication of complex multilateral structures has been hindered by difficulties in controlling the interfaces between inks and supports. In this work, an in-depth study of the rheological properties and interfacial stabilities between a nanoclay-modified support and silicone-based inks enabled a better understanding of the impact printing parameters have on the extruded filament morphology, and thus on printing resolutions. With these improvements, the fabrication of functional multimaterial pneumatic components applied to soft robotics could be demonstrated, exhibiting superior capabilities compared to casting or traditional extrusion-based additive manufacturing in terms of geometric freedom (overhanging and multimaterial structures), tunability of the component's functionality, and robustness between different phases. Overall, the full exploitation of FL-3DP advantages enables a broader design space for features and functionalities in soft robotic components that require complex and robust combinations of materials.

Fluid Bath-Assisted 3D Printing for Biomedical Applications: From Pre- to Postprinting Stages

Fluid bath-assisted three-dimensional (3D) printing is an innovative 3D printing strategy that extrudes liquid ink materials into a fluid bath to form various 3D configurations. Since the support bath can provide in situ support, extruded filaments are able to freely construct complex 3D structures. Meanwhile, the supporting function of the fluid bath decreases the dependence of the ink material's cross-linkability, thus broadening the material selections for biomedical applications. Fluid bath-assisted 3D printing can be divided into two subcategories: embedded 3D printing and support bath-enabled 3D printing. This review will introduce and discuss three main manufacturing processes, or stages, for these two strategies. The stages that will be discussed include preprinting, printing, and postprinting. In the preprinting stage, representative fluid bath materials are introduced and the bath material preparation methods are also discussed. In addition, the design criteria of fluid bath materials including biocompatibility, rheological properties, physical/chemical stability, hydrophilicity/hydrophobicity, and other properties are proposed in order to guide the selection and design of future fluid bath materials. For the printing stage, some key technical issues discussed in this review include filament formation mechanisms in a fluid bath, effects of nozzle movement on printed structures, and design strategies for printing paths. In the postprinting stage, some commonly used postprinting processes are introduced. Finally, representative biomedical applications of fluid bath-assisted 3D printing, such as standalone organoids/tissues, biomedical microfluidic devices, and wearable and bionic devices, are summarized and presented.

Simulated filament shapes in embedded 3D printing

Embedded 3D printing, wherein fluid inks are extruded into support baths, has enabled the manufacture of complex, custom structures ranging from cell-laden tissue analogues to soft robots. This method encompasses two techniques: embedded ink writing (EIW), where filaments are extruded, and embedded droplet printing (EDP), where droplets are suspended. Materials for embedded 3D printing can be Newtonian, but often both the ink and the support bath are yield stress fluids, following elastic behavior below the yield stress and shear-thinning, viscous behavior above the yield stress. The effect of surface tension on print quality has been debated, as inks have been printed into supports at high and low surface tensions. In order to guide material selection for embedded 3D printing and identify key scaling relationships that influence print quality, this study investigates the role of ink rheology, support rheology, and surface tension on the morphology of single filaments. Numerical simulations in OpenFOAM demonstrate that at low viscosities, surface tension controls the filament morphology. Where capillarity is suppressed, the ratio of the local ink and support viscosities and the shape of the yield surface in the support control the filament shape. Herschel-Bulkley support fluids (yield stress fluids) produce more stable, accurately positioned filaments than Newtonian supports. In the short term, non-zero surface tensions can suppress filament shape defects in EIW and are essential for producing droplets in EDP.

Emergence of FRESH 3D printing as a platform for advanced tissue biofabrication

In tissue engineering, an unresolved challenge is how to build complex 3D scaffolds in order to recreate the structure and function of human tissues and organs. Additive manufacturing techniques, such as 3D bioprinting, have the potential to build biological material with unprecedented spatial control; however, printing soft biological materials in air often results in poor fidelity. Freeform Reversible Embedding of Suspended Hydrogels (FRESH) is an embedded printing approach that solves this problem by extruding bioinks within a yield-stress support bath that holds the bioinks in place until cured. In this Perspective, we discuss the challenges of 3D printing soft and liquid-like bioinks and the emergence for FRESH and related embedded printing techniques as a solution. This includes the development of FRESH and embedded 3D printing within the bioprinting field and the rapid growth in adoption, as well as the advantages of FRESH printing for biofabrication and the new research results this has enabled. Specific focus is on the customizability of the FRESH printing technique where the chemical composition of the yield-stress support bath and aqueous phase crosslinker can all be tailored for printing a wide range of bioinks in complex 3D structures. Finally, we look ahead at the future of FRESH printing, discussing both the challenges and the opportunities that we see as the biofabrication field develops.

Freeform 3D printing of vascularized tissues: Challenges and strategies

In recent years, freeform three-dimensional (3D) printing has led to significant advances in the fabrication of artificial tissues with vascularized structures. This technique utilizes a supporting matrix that holds the extruded printing ink and ensures shape maintenance of the printed 3D constructs within the prescribed spatial precision. Since the printing nozzle can be translated omnidirectionally within the supporting matrix, freeform 3D printing is potentially applicable for the fabrication of complex 3D objects, incorporating curved, and irregular shaped vascular networks. To optimize freeform 3D printing quality and performance, the rheological properties of the printing ink and supporting matrix, and the material matching between them are of paramount importance. In this review, we shall compare conventional 3D printing and freeform 3D printing technologies for the fabrication of vascular constructs, and critically discuss their working principles and their advantages and disadvantages. We also provide the detailed material information of emerging printing inks and supporting matrices in recent freeform 3D printing studies. The accompanying challenges are further discussed, aiming to guide freeform 3D printing by the effective design and selection of the most appropriate materials/processes for the development of full-scale functional vascularized artificial tissues.

Freeform 3D printing of soft matters: recent advances in technology for biomedical engineering

In the last decade, an emerging three-dimensional (3D) printing technique named freeform 3D printing has revolutionized the biomedical engineering field by allowing soft matters with or without cells to be printed and solidified with high precision regardless of their poor self-supportability. The key to this freeform 3D printing technology is the supporting matrices that hold the printed soft ink materials during omnidirectional writing and solidification. This approach not only overcomes structural design restrictions of conventional layer-by-layer printing but also helps to realize 3D printing of low-viscosity or slow-curing materials. This article focuses on the recent developments in freeform 3D printing of soft matters such as hydrogels, cells, and silicone elastomers, for biomedical engineering. Herein, we classify the reported freeform 3D printing systems into positive, negative, and functional based on the fabrication process, and discuss the rheological requirements of the supporting matrix in accordance with the rheological behavior of counterpart inks, aiming to guide development and evaluation of new freeform printing systems. We also provide a brief overview of various material systems used as supporting matrices for freeform 3D printing systems and explore the potential applications of freeform 3D printing systems in different areas of biomedical engineering.

Nanomaterial Patterning in 3D Printing

The synergistic integration of nanomaterials with 3D printing technologies can enable the creation of architecture and devices with an unprecedented level of functional integration. In particular, a multiscale 3D printing approach can seamlessly interweave nanomaterials with diverse classes of materials to impart, program, or modulate a wide range of functional properties in an otherwise passive 3D printed object. However, achieving such multiscale integration is challenging as it requires the ability to pattern, organize, or assemble nanomaterials in a 3D printing process. This review highlights the latest advances in the integration of nanomaterials with 3D printing, achieved by leveraging mechanical, electrical, magnetic, optical, or thermal phenomena. Ultimately, it is envisioned that such approaches can enable the creation of multifunctional constructs and devices that cannot be fabricated with conventional manufacturing approaches.

A mini-review of embedded 3D printing: supporting media and strategies

Embedded 3D printing is an additive manufacturing method based on a material extrusion strategy.