3D printing of self-assembling thermoresponsive nanoemulsions into hierarchical mesostructured hydrogels

Digital light processing 3D printing of high-fidelity and versatile hydrogels via in situ phase separation

Recently, digital light processing (DLP) 3D printing has garnered significant interest for fabricating high-fidelity hydrogels. However, the intrinsic weak and loose network of hydrogels, coupled with uncontrollable light projection, leads to low printing resolution and restricts their broader applications. Herein, we propose a straightforward DLP 3D printing strategy utilizing in situ phase separation to produce high-fidelity, high-modulus, and biocompatible hydrogels. By selecting acrylamide monomers with poor compatibility within a polyvinyl pyrrolidone (PVP) network during polymerization, we create phase-separated domains within polyacrylamide (PAM) that effectively inhibit ultraviolet (UV) light transmission. This regulation of UV light distribution results in anhydrous inks with exceptional properties: ultra-high resolution (1.5 μm), ultra-high modulus (1043 MPa), and high strength (70.0 MPa). Upon hydration, the modulus and strength of the hydrogels decrease to approximately 4000 times those of the anhydrous gels, exhibiting high mechano-moisture sensitivity suitable for actuator applications. Additionally, the DLP 3D-printed hydrogels, featuring micro-scale structures, demonstrate good biocompatibility and facilitate nutrient transport for cell proliferation. This versatile DLP 3D printing strategy paves the way for the fabrication of high-fidelity and multifunctional hydrogels.

Porous biomaterials for tissue engineering: a review

The field of biomaterials has grown rapidly over the past decades. Within this field, porous biomaterials have played a remarkable role in: (i) enabling the manufacture of complex three-dimensional structures; (ii) recreating mechanical properties close to those of the host tissues; (iii) facilitating interconnected structures for the transport of macromolecules and cells; and (iv) behaving as biocompatible inserts, tailored to either interact or not with the host body. This review outlines a brief history of the development of biomaterials, before discussing current materials proposed for use as porous biomaterials and exploring the state-of-the-art in their manufacture. The wide clinical applications of these materials are extensively discussed, drawing on specific examples of how the porous features of such biomaterials impact their behaviours, as well as the advantages and challenges faced, for each class of the materials.

Multi-layer 3D printed dipeptide-based low molecular weight gels

We describe the direct 3D printing of dipeptide hydrogels, forming layers from gels prepared from different dipeptides. The dipeptides self-assemble into fibres that lead to very different microstructures letting us differentiate between the gels. We show how the mechanical properties of the overall 3D printed structures are affected by the composition of each of the layers, allowing us to build up structures with different microstructure and stiffness. We also discuss the interface between layers formed from different gelators, showing that the gels remain independent from neighbouring printed material, even when prepared in very close proximity.

Strength of fluid-filled soft composites across the elastofracture length

Materials that utilize heterogeneous microstructures to control macroscopic mechanical response are ubiquitous in nature. Yet, translating nature's lessons to create synthetic soft solids has remained challenging. This is largely due to the limited synthetic routes available for creating soft composites, particularly with submicron features, as well as uncertainty surrounding the role of such a microstructured secondary phase in determining material behavior. This work leverages recent advances in the development of photocrosslinkable thermogelling nanoemulsions to produce composite hydrogels with a secondary phase assembled at well controlled length scales ranging from tens of nm to tens of μm. Through analysis of the mechanical response of these fluid-filled composite hydrogels, it is found that the size scale of the secondary phase has a profound impact on the strength when at or above the elastofracture length. Moreover, this work shows that mechanical integrity of fluid-filled soft solids can be sensitive to the size scale of the secondary phase.

Nanoemulsions: Formulation, characterization, biological fate, and potential role against COVID-19 and other viral outbreaks

Viral diseases are emerging as global threats. Severe acute respiratory syndrome coronavirus-2 (SARS-CoV-2), that causes coronavirus disease (COVID-19), has severe global impacts. Safety, dosage, and potency of vaccines recently approved for emergency use against SARS-CoV-2 need further evaluation. There is still no effective treatment against COVID-19; therefore, safe, and effective vaccines or therapeutics against SARS-CoV-2 are urgently needed. Oil-in-water nanoemulsions (O/W NEs) are emerging as sophisticated, protective, and therapeutic platforms. Encapsulation capacity, which offers better drug pharmacokinetics, coupled with the tunable surfaces present NEs as promising tools for pharmaceutical applications. The challenges facing drug discovery, and the advancements of NEs in drug delivery demonstrate the potential of NEs against evolving diseases, like COVID-19. Here we summarize current COVID-19 knowledge and discuss the composition, stability, preparation, characterization, and biological fate of O/W NEs. We also provide insights into NE structural-functional properties that may contribute to therapeutic or preventative solutions against COVID-19.

Detection and Tracking Volumes of Interest in 3D Printed Tissue Engineering Scaffolds using 4D Imaging Modalities

Additive manufacturing (AM) platforms allow the production of patient tissue engineering scaffolds with desirable architectures. Although AM platforms offer exceptional control on architecture, post-processing methods such as sintering and freeze-drying often deform the printed scaffold structure. In-situ 4D imaging can be used to analyze changes that occur during post-processing. Visualization and analysis of changes in selected volumes of interests (VOIs) over time are essential to understand the underlining mechanisms of scaffold deformations. Yet, automated detection and tracking of VOIs in the 3D printed scaffold over time using 4D image data is currently an unsolved image processing task. This paper proposes a new image processing technique to segment, detect and track volumes of interest in 3D printed tissue engineering scaffolds. The method is validated using a 4D synchrotron sourced microCT image data captured during the sintering of bioactive glass scaffolds in-situ. The proposed method will contribute to the development of scaffolds with controllable designs and optimum properties for the development of patient-specific scaffolds.

Sol/gel transition of oil/water microemulsions controlled by surface grafted triblock copolymer dodecyl-PEO227-dodecyl: molecular dynamics simulations with experimentally validated interaction potential

We studied a large range of identical spherical oil/water microemulsion (O/W-MI) volume fractions. The O/W-MIs are stabilized by cetylpyridinium chloride ionic surfactant (CpCl) and octanol cosurfactant and dispersed in salt water. We grafted different numbers of dodecyl-(polyEthylene oxide)227-dodecyl triblock copolymer that we note (n(D-PEO227-D)), where n varies from 0 to 12. We accomplished the grafting process by replacing a small amount of CpCl and octanol with the appropriate n(D-PEO227-D). The aim is to determine the interaction/structure relationship of the covered microemulsions. Precisely, we are interested in a quantitative investigation of the influence of volume fraction Φ, temperature (T), and n(D-PEO227-D) on the microemulsion sol/gel transition. To this end, we first study the uncoated microemulsion structure depending only on Φ. Second, we determine the coated microemulsions structure as a function of n(D-PEO227-D) for different Φ. Third, we examine the effect of temperature on the uncoated and coated microemulsion. We show that the sol/gel transition is controlled by the three main parameters, Φ, T, and n(D-PEO227-D). Accordingly, the uncoated microemulsion sol/gel transition, at ambient temperature, occurred for Φ ≃ 33.65%. By increasing Φ, the O/W-MIs show a glass state, which occurs, along with the gel state, at Φ ≃ 37% and arises clearly at Φ ≃ 60%. The coated O/W-MI sol/gel transition is found to be linearly dependent on n(D-PEO227-D) and takes place for Φ ≃ 26.5% for n(D-PEO227-D) = 12. Ordinarily, the decrease in temperature leads to gel formation of microemulsions for low Φ. Additionally, in this work, we found that the gelation temperature increases linearly with n(D-PEO227-D). Thus, the parameter n(D-PEO227-D) can control the sol/gel transition of the O/W-MIs at ambient temperature and moderate Φ.

Additively manufactured BaTiO3 composite scaffolds: A novel strategy for load bearing bone tissue engineering applications

Piezoelectric ceramics, such as BaTiO₃, have gained considerable attention in bone tissue engineering applications thanks to their biocompatibility, ability to sustain a charged surface as well as improve bone cells' adhesion and proliferation. However, the poor processability and brittleness of these materials hinder the fabrication of three-dimensional scaffolds for load bearing tissue engineering applications. For the first time, this study focused on the fabrication and characterisation of BaTiO₃ composite scaffolds by using a multi-material 3D printing technology. Polycaprolactone (PCL) was selected and used as dispersion phase for its low melting point, easy processability and wide adoption in bone tissue engineering. The proposed single-step extrusion-based strategy enabled a faster and solvent-free process, where raw materials in powder forms were mechanically mixed and subsequently fed into the 3D printing system for further processing. PCL, PCL/hydroxyapatite and PCL/BaTiO₃ composite scaffolds were successfully produced with high level of consistency and an inner architecture made of seamlessly integrated layers. The inclusion of BaTiO₃ ceramic particles (10% wt.) significantly improved the mechanical performance of the scaffolds (54 ± 0.5 MPa) compared to PCL/hydroxyapatite scaffolds (40.4 ± 0.1 MPa); moreover, the presence of BaTiO₃ increased the dielectric permittivity over the entire frequency spectrum and tested temperatures. Human osteoblasts Saos-2 were seeded on scaffolds and cellular adhesion, proliferation, differentiation and deposition of bone-like extracellular matrix were evaluated. All tested scaffolds (PCL, PCL/hydroxyapatite and PCL/BaTiO₃) supported cell growth and viability, preserving the characteristic cellular osteoblastic phenotype morphology, with PCL/BaTiO₃ composite scaffolds exhibiting higher mineralisation (ALP activity) and deposited bone-like extracellular matrix (osteocalcin and collagen I). The single-step multi-material additive manufacturing technology used for the fabrication of electroactive PCL/BaTiO₃ composite scaffolds holds great promise for sustainability (reduced material waste and manufacturing costs) and it importantly suggests PCL/BaTiO₃ scaffolds as promising candidates for load bearing bone tissue engineering applications to solve unmet clinical needs.

High Internal Phase Emulsion for Food-Grade 3D Printing Materials

Three-dimensional printing (3DP) has attracted significant attention for its use in additive manufacturing techniques because it provides customizability and flexibility for fabricating structures with arbitrary shapes. Certain applications in the food and medicine industries require 3D printable materials that are both biocompatible and biodegradable. Consequently, this study reports 3D printable materials constructed from food-grade high internal phase emulsions (HIPEs). The studied HIPEs (phase ratio 85%) were stabilized by the efficient adsorption behavior of cod proteins (concentration range, 10-50 mg mL^-1) at the oil-water interface. The stability of the oil-in-water HIPEs was improved by the formation of a concentration-dependent percentage of adsorbed proteins and cross-linking networks, and homogeneous and self-supporting structures were generated after 7 days of storage at 4 °C. The gel-like shear thinning rheological behavior induced by the cross-linking networks in the studied HIPEs can be tuned to obtain the desired printability and extrudability during 3DP. In the present study, the HIPEs stabilized with 50 mg mL^-1 of cod proteins exhibited the highest printing resolution, gel strength, hardness, adhesiveness, and chewiness during 3DP. These food-grade HIPE inks have the potential to diversify the applications of 3DP in foods, cosmetics, drug delivery systems, and packaging materials.

Tuning Material Properties of Nanoemulsion Gels by Sequentially Screening Electrostatic Repulsions and Then Thermally Inducing Droplet Bridging

Nanoemulsions are widely used in applications such as food products, cosmetics, pharmaceuticals, and enhanced oil recovery for which the ability to engineer material properties is desirable. Moreover, nanoemulsions are emergent model colloidal systems because of the ease in synthesizing monodisperse samples, flexibility in formulations, and tunable material properties. In this work, we study a nanoemulsion system previously developed by our group in which gelation occurs through thermally induced polymer bridging of droplets. We show here that the same system can undergo a sol-gel transition at room temperature through the addition of salt, which screens the electrostatic interaction and allows the system to assemble via depletion attraction. We systematically study how the addition of salt followed by a temperature jump can influence the resulting microstructures and rheological properties of the nanoemulsion system. We show that the salt-induced gel at room temperature can dramatically restructure when the temperature is suddenly increased and achieves a different gelled state. Our results offer a route to control the material properties of an attractive colloidal system by carefully tuning the interparticle potentials and sequentially triggering the colloidal self-assembly. The control and understanding of the material properties can be used for designing hierarchically structured hydrogels and complex colloid-based materials for advanced applications.

3D Printing Latex: A Route to Complex Geometries of High Molecular Weight Polymers

Vat photopolymerization (VP) additive manufacturing fabricates intricate geometries with excellent resolution; however, high molecular weight polymers are not amenable to VP due to concomitant high solution and melt viscosities. Thus, a challenging paradox arises between printability and mechanical performance. This report describes concurrent photopolymer and VP system design to navigate this paradox with the unprecedented use of polymeric colloids (latexes) that effectively decouple the dependency of viscosity on molecular weight. Photocrosslinking of a continuous-phase scaffold, which surrounds the latex particles, combined with in situ computer-vision print parameter optimization, which compensates for light scattering, enables high-resolution VP of high molecular weight polymer latexes as particle-embedded green bodies. Thermal post-processing promotes coalescence of the dispersed particles throughout the scaffold, forming a semi-interpenetrating polymer network without loss in part resolution. Printing a styrene-butadiene rubber latex, a previously inaccessible elastomer composition for VP, exemplified this approach and yielded printed elastomers with precise geometry and tensile extensibilities exceeding 500%.

3D Printing Customized Optical Lens in Minutes

Synergizing grayscale photopolymerization and meniscus coating processes, rapid 3D printing of optical lenses is reported previously using projection microstereolithography (PμSL) process. Despite its 14 000-fold-improved printing speed over the femtosecond 3D printing process, PμSL still consumes significant amount of the fabrication time for precise recoating 5 μm thick fresh resin layers. At the reported speed of 24.54 mm3 h-1, 3D printing of the millimeter-size lenses still takes hours. To further improve the printing speed, the microcontinuous liquid interface production process is implemented to eliminate the time-consuming resin recoating step. However, the micrometer-size pores in the Teflon membrane needed for oxygen transportation are found to completely spoil the surface smoothness. The use of polydimethylsiloxane thin film possessing much refined nanoscopic porosities as the functional substitute of Teflon membrane is reported to significantly reduce the surface roughness to 13.7 nm. 3D printing of 3 mm high aspherical lens in ≈2 min at a 200-fold-improved speed at 4.85 × 103 mm3 h-1 is demonstrated. The 3D printed aspherical lens has the demonstrated imaging resolution of 3.10 μm. This work represents a significant step in tackling the speed-accuracy trade-off of 3D printing process and thus enables rapid fabrication of customized optical components.

Light and latex: advances in the photochemistry of polymer colloids

Unparalleled temporal and spatial control of colloidal chemical processes introduces immense potential for the manufacturing, modification, and manipulation of latex particles.

Colloidal Gelation through Thermally Triggered Surfactant Displacement

Colloidal systems that undergo gelation attract much attention in both fundamental studies and practical applications. Rational tuning of interparticle interactions allows researchers to precisely engineer colloidal material properties and microstructures. Here, contrary to the traditional approaches where modulating attractive interactions is the major focus, we present a platform wherein colloidal gelation is controlled by tuning repulsive interactions. By including amphiphilic oligomers in colloidal suspensions, the ionic surfactants on the colloids are replaced by the nonionic oligomer surfactants at elevated temperatures, leading to a decrease in electrostatic repulsion. The mechanism is examined by carefully characterizing the colloids, and subsequently allowing the construction of interparticle potentials to capture the material behaviors. With the thermally triggered surfactant displacement, the dispersion assembles into a macroporous viscoelastic network and the gelling mechanism is robust over a wide range of compositions, colloid sizes, and component chemistries. This stimulus-responsive gelation platform is general and offers new strategies to engineer complex viscoelastic soft materials.

Freestanding 3D Mesostructures, Functional Devices, and Shape-Programmable Systems Based on Mechanically Induced Assembly with Shape Memory Polymers

Capabilities for controlled formation of sophisticated 3D micro/nanostructures in advanced materials have foundational implications across a broad range of fields. Recently developed methods use stress release in prestrained elastomeric substrates as a driving force for assembling 3D structures and functional microdevices from 2D precursors. A limitation of this approach is that releasing these structures from their substrate returns them to their original 2D layouts due to the elastic recovery of the constituent materials. Here, a concept in which shape memory polymers serve as a means to achieve freestanding 3D architectures from the same basic approach is introduced, with demonstrated ability to realize lateral dimensions, characteristic feature sizes, and thicknesses as small as ≈500, 10, and 5 µm simultaneously, and the potential to scale to much larger or smaller dimensions. Wireless electronic devices illustrate the capacity to integrate other materials and functional components into these 3D frameworks. Quantitative mechanics modeling and experimental measurements illustrate not only shape fixation but also capabilities that allow for structure recovery and shape programmability, as a form of 4D structural control. These ideas provide opportunities in fields ranging from micro-electromechanical systems and microrobotics, to smart intravascular stents, tissue scaffolds, and many others.

Thermal processing of thermogelling nanoemulsions as a route to tune material properties

Many soft matter systems have properties which depend on their processing history. It is generally accepted that material properties can be finely tuned by carefully directing self-assembly. However, for gelling colloidal systems, it is difficult to characterize such path-dependent effects since the colloidal attraction is often provided by adding another component to the system such as salts or depletants. Therefore, studies of and an understanding of the role of processing on the material properties of attractive colloidal systems are largely lacking. In this work, we systematically studied how processing greatly influences the properties and the microstructures of model attractive colloidal systems. We perform experiments using a thermogelling nanoemulsion as a model system where the isotropic attraction can be precisely tuned via the temperature. The effects of processing conditions on gel formation and properties is tested by performing well-designed sequential temperature jumps. By properly controlling the thermal history, we demonstrate that properties of colloidal gels can be beyond the limit set by direct quenching, which has been a major focus in literature, and that otherwise slow aging of the system associated with a decrease in elasticity can be prevented. Our results provide new experimental evidence of path-dependent rheology and associated microstructures in attractive colloidal systems and provide guidance to future applications in manufacturing complex colloid-based materials.

DIY 3D Microparticle Generation from Next Generation Optofluidic Fabrication

Complex-shaped microparticles can enhance applications in drug delivery, tissue engineering, and structural materials, although techniques to fabricate these particles remain limited. A microfluidics-based process called optofluidic fabrication that utilizes inertial flows and ultraviolet polymerization has shown great potential for creating highly 3D-shaped particles in a high-throughput manner, but the particle dimensions are mainly at the millimeter scale. Here, a next generation optofluidic fabrication process is presented that utilizes on-the-fly fabricated multiscale fluidic channels producing customized sub-100 µm 3D-shaped microparticles. This flexible design scheme offers a user-friendly platform for rapid prototyping of new 3D particle shapes, providing greater potential for creating impactful engineered microparticles.

Applications of 3D printing in cancer

The tumor heterogeneity and interindividual variability is a major problem when treating cancer as every patient responds in a different way to the current drug therapies. 3D printing is a tool that can hamper the issues faced in cancer patients allowing for individualization of treatment by the production of in vitro models with microenvironments mimicking more closely real cancer conditions facilitating complex therapies. Further improvements are required, for example the development of biocompatible bioinks or need for vascularization. The journey from bench to bedside is challenging from the regulatory point of view where the establishment of manufacturing guidelines, quality systems and safety of use and administration of personalized medicines remains unclear. This review will provide an insight into the major applications of 3D printing in cancer both in the development of in vitro cancer models as well as personalized medicines for cancer patients focused on hydrogels and therapeutic implants.

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Nanogels for Pharmaceutical and Biomedical Applications and Their Fabrication Using 3D Printing Technologies

Nanogels are hydrogels formed by connecting nanoscopic micelles dispersed in an aqueous medium, which give an opportunity for incorporating hydrophilic payloads to the exterior of the micellar networks and hydrophobic payloads in the core of the micelles. Biomedical and pharmaceutical applications of nanogels have been explored for tissue regeneration, wound healing, surgical device, implantation, and peroral, rectal, vaginal, ocular, and transdermal drug delivery. Although it is still in the early stages of development, due to the increasing demands of precise nanogel production to be utilized for personalized medicine, biomedical applications, and specialized drug delivery, 3D printing has been explored in the past few years and is believed to be one of the most precise, efficient, inexpensive, customizable, and convenient manufacturing techniques for nanogel production.

Optimising low molecular weight hydrogels for automated 3D printing

Hydrogels prepared from low molecular weight gelators (LMWGs) are formed as a result of hierarchical intermolecular interactions between gelators to form fibres, and then further interactions between the self-assembled fibres via physical entanglements, as well as potential branching points. These interactions can allow hydrogels to recover quickly after a high shear rate has been applied. There are currently limited design rules describing which types of morphology or rheological properties are required for a LMWG hydrogel to be used as an effective, printable gel. By preparing hydrogels with different types of fibrous network structures, we have been able to understand in more detail the morphological type which gives rise to a 3D-printable hydrogel using a range of techniques, including rheology, small angle scattering and microscopy.

Multiple particle tracking study of thermally-gelling nanoemulsions

We perform multiple particle tracking (MPT) on a thermally-gelling oil-in-water nanoemulsion system. Carboxylated and plain polystyrene probes are used to investigate the role of colloidal probe size and surface chemistry on MPT in the nanoemulsion system. As temperature increases, hydrophobic groups of PEG-based gelators (PEGDA) partition into the oil/water interface and bridge droplets. This intercolloidal attraction generates a wide variety of microstructures consisting of droplet-rich and droplet-poor phases. By tailoring the MPT colloidal probe surface chemistry, we can control the residence of probes in each domain, thus allowing us to independently probe each phase. Our results show stark differences in probe dynamics in each domain. For certain conditions, the mean squared displacement (MSD) can differ by over four orders of magnitude for the same probe size but different surface chemistry. Carboxylated probe surface chemistries result in "slippery" probes while plain polystyrene probes appear to tether to the nanoemulsion gel network. We also observe probe hopping between pores in the gel for carboxylated probes. Our approach demonstrates that probes with different surface chemistries are useful in probing the local regions of a colloidal gel and allows the measurement of local properties within structurally heterogeneous hydrogels.