Direct sound printing

Ultrasound Mediated Polymerization for Cell Delivery, Drug Delivery, and 3D Printing

Safe and accurate in situ delivery of biocompatible materials is a fundamental requirement for many biomedical applications. These include sustained and local drug release, implantation of acellular biocompatible scaffolds, and transplantation of cells and engineered tissues for functional restoration of damaged tissues and organs. The common practice today includes highly invasive operations with major risks of surgical complications including adjacent tissue damage, infections, and long healing periods. In this work, a novel non-invasive delivery method is presented for scaffold, cells, and drug delivery deep into the body to target inner tissues. This technology is based on acousto-sensitive materials which are polymerized by ultrasound induction through an external transducer in a rapid and local fashion without additional photoinitiators or precursors. The applicability of this technology is demonstrated for viable and functional cell delivery, for drug delivery with sustained release profiles, and for 3D printing. Moreover, the mechanical properties of the delivered scaffold can be tuned to the desired target tissue as well as controlling the drug release profile. This promising technology may shift the paradigm for local and non-invasive material delivery approach in many clinical applications as well as a new printing method - "acousto-printing" for 3D printing and in situ bioprinting.

Self-enhancing sono-inks enable deep-penetration acoustic volumetric printing

Volumetric printing, an emerging additive manufacturing technique, builds objects with enhanced printing speed and surface quality by forgoing the stepwise ink-renewal step. Existing volumetric printing techniques almost exclusively rely on light energy to trigger photopolymerization in transparent inks, limiting material choices and build sizes. We report a self-enhancing sonicated ink (or sono-ink) design and corresponding focused-ultrasound writing technique for deep-penetration acoustic volumetric printing (DAVP). We used experiments and acoustic modeling to study the frequency and scanning rate-dependent acoustic printing behaviors. DAVP achieves the key features of low acoustic streaming, rapid sonothermal polymerization, and large printing depth, enabling the printing of volumetric hydrogels and nanocomposites with various shapes regardless of their optical properties. DAVP also allows printing at centimeter depths through biological tissues, paving the way toward minimally invasive medicine.

Functional PDMS Elastomers: Bulk Composites, Surface Engineering, and Precision Fabrication

Polydimethylsiloxane (PDMS)-the simplest and most common silicone compound-exemplifies the central characteristics of its class and has attracted tremendous research attention. The development of PDMS-based materials is a vivid reflection of the modern industry. In recent years, PDMS has stood out as the material of choice for various emerging technologies. The rapid improvement in bulk modification strategies and multifunctional surfaces has enabled a whole new generation of PDMS-based materials and devices, facilitating, and even transforming enormous applications, including flexible electronics, superwetting surfaces, soft actuators, wearable and implantable sensors, biomedicals, and autonomous robotics. This paper reviews the latest advances in the field of PDMS-based functional materials, with a focus on the added functionality and their use as programmable materials for smart devices. Recent breakthroughs regarding instant crosslinking and additive manufacturing are featured, and exciting opportunities for future research are highlighted. This review provides a quick entrance to this rapidly evolving field and will help guide the rational design of next-generation soft materials and devices.

Additive Manufacturing of Biodegradable Hemp-Reinforced Polybutylene Succinate (PBS) and Its Mechanical Characterization

The additive manufacturing of natural fibre-reinforced polymers is a pivotal method in developing sustainable engineering solutions. Using the fused filament fabrication method, the current study investigates the additive manufacturing of hemp-reinforced polybutylene succinate (PBS) alongside its mechanical characterization. Two types of hemp reinforcement are considered: short fibres (max. length smaller than 2 mm) and long fibres (max. length smaller than 10 mm), which are compared against non-reinforced (pure) PBS. A detailed analysis is performed regarding the determination of suitable 3D printing parameters (overlap, temperature, nozzle diameter). In a comprehensive experimental study, additionally to general analyses regarding the influence of hemp reinforcement on the mechanical behaviour, the effect of printing parameters is determined and discussed. Introducing an overlap in the additive manufacturing of the specimens results in improved mechanical performance. The study highlights that the Young's modulus of PBS can be improved by 63% by introducing hemp fibres in conjunction with overlap. In contrast, hemp fibre reinforcement reduces the tensile strength of PBS, while this effect is less pronounced considering overlap in the additive manufacturing process.

Additive Manufacturing by Heating at a Patterned Photothermal Interface

Direct additive manufacturing (AM) of commercial silicones is an unmet need with high demand. We report a new technology, heating at a patterned photothermal interface (HAPPI), which achieves AM of commercial thermoset resins without any chemical modifications. HAPPI integrates desirable aspects of stereolithography with the thermally driven chemical modalities of commercial silicone formulations. In this way, HAPPI combines the geometric advantages of vat photopolymerization with the materials properties of, for example, injection molded silicones. We describe the realization of the new technology, HAPPI printing using a commercial Sylgard 184 polydimethylsiloxane resin, comparative analyses of material properties, and demonstration of HAPPI in targeted applications.

Fabrication of biconvex spherical and aspherical lenses using 3D printing

In this work, we present the methods of fabrication and characterization of biconvex spherical and aspherical lenses with 25 and 50 mm diameters that have been created via additive technology using a Formlabs Form 3 stereolithography 3D printer. After the prototypes are postprocessed, fabrication errors ≤2.47% for the radius of curvature, the optical power, and the focal length are obtained. We show eye fundus images captured with an indirect ophthalmoscope using the printed biconvex aspherical prototypes, proving the functionality of both the fabricated lenses and the proposed method, which is fast and low-cost.

Advanced supramolecular design for direct ink writing of soft materials

The exciting advancements in 3D-printing of soft materials are changing the landscape of materials development and fabrication. Among various 3D-printers that are designed for soft materials fabrication, the direct ink writing (DIW) system is particularly attractive for chemists and materials scientists due to the mild fabrication conditions, compatibility with a wide range of organic and inorganic materials, and the ease of multi-materials 3D-printing. Inks for DIW need to possess suitable viscoelastic properties to allow for smooth extrusion and be self-supportive after printing, but molecularly facilitating 3D printability to functional materials remains nontrivial. While supramolecular binding motifs have been increasingly used for 3D-printing, these inks are largely optimized empirically for DIW. Hence, this review aims to establish a clear connection between the molecular understanding of the supramolecularly bound motifs and their viscoelastic properties at bulk. Herein, extrudable (but not self-supportive) and 3D-printable (self-supportive) polymeric materials that utilize noncovalent interactions, including hydrogen bonding, host-guest inclusion, metal-ligand coordination, micro-crystallization, and van der Waals interaction, have been discussed in detail. In particular, the rheological distinctions between extrudable and 3D-printable inks have been discussed from a supramolecular design perspective. Examples shown in this review also highlight the exciting macroscale functions amplified from the molecular design. Challenges associated with the hierarchical control and characterization of supramolecularly designed DIW inks are also outlined. The perspective of utilizing supramolecular binding motifs in soft materials DIW printing has been discussed. This review serves to connect researchers across disciplines to develop innovative solutions that connect top-down 3D-printing and bottom-up supramolecular design to accelerate the development of 3D-print soft materials for a sustainable future.

3D printing of thermosets with diverse rheological and functional applicabilities

Thermosets such as silicone are ubiquitous. However, existing manufacturing of thermosets involves either a prolonged manufacturing cycle (e.g., reaction injection molding), low geometric complexity (e.g., casting), or limited processable materials (e.g., frontal polymerization). Here, we report an in situ dual heating (ISDH) strategy for the rapid 3D printing of thermosets with complex structures and diverse rheological properties by incorporating direct ink writing (DIW) technique and a heating-accelerated in situ gelation mechanism. Enabled by an integrated Joule heater at the printhead, extruded thermosetting inks can quickly cure in situ, allowing for DIW of various thermosets with viscosities spanning five orders of magnitude, printed height over 100 mm, and high resolution of 50 μm. We further demonstrate DIW of a set of heterogenous thermosets using multiple functional materials and present a hybrid printing of a multilayer soft electronic circuit. Our ISDH strategy paves the way for fast manufacturing of thermosets for various emerging fields.

Three-dimensional printing of smart constructs using stimuli-responsive biomaterials: A future direction of precision medicine

Three-dimensional (3D) printing, which is a valuable technique for the fabrication of tissue-engineered constructs and biomedical devices with complex architectures, has brought about considerable progress in regenerative medicine, drug delivery, and diagnosis of diseases. However, because of the static and inanimate properties of conventional 3D-printed structures, it is difficult to use them in therapies for active and precise medicine, such as improved tissue regeneration, targeted or controlled drug delivery, and advanced pathophysiological monitoring. The integration of stimuli-responsive biomaterials into 3D printing provides a potential strategy for designing and building smart constructs that exhibit programmed functions and controllable changes in properties in response to exogenous and autogenous stimuli. These features make 3D-printed smart constructs the next generation of tissue-engineered products. In this review, we introduce the prevalent 3D printing techniques (with an emphasis on the differences between 3D printing and bioprinting, and biomaterials and bioink), the working principle of each technique, and the advantages of using 3D printing for the fabrication of smart constructs. Stimuli-responsive biomaterials that are widely used for 3D printing of smart constructs are categorized, followed by a summary of their applications in tissue regeneration, drug delivery, and biosensors. Finally, the challenges and future perspectives of 3D-printed smart constructs are discussed.