High-speed two-photon polymerization 3D printing with a microchip laser at its fundamental wavelength

Additive manufacturing in spatial patterning for spinal cord injury treatment

Combinatorial treatments integrating cells and biomolecules within scaffolds have been investigated to address the multifactorial nature of spinal cord injury (SCI). Current regenerative treatments have been ineffective as they do not consider the spatial positions of various cell types to effectively form functional neural pathways. Emulating the complex heterogeneity of cells in the native spinal cord requires translating the existing biological understanding of spatial patterning in neural development, as well as the influence of biomolecule and mechanical patterning on regional specification and axonal regeneration, to engineer a scaffold for spinal cord regeneration. This review explores the potential of 3D bioprinting to precisely control material, cell and drug patterns in scaffolds, achieving spatial phenotype specification and providing axonal guidance to form appropriate connections. We also discuss the application of extrusion-based and digital light processing bioprinting in integrating mechanical, chemical and biological cues within a scaffold to advance spatially patterned 3D bioprinted scaffold, as well as current challenges and future perspectives in these bioengineering strategies.

Conductive Biocomposite Made by Two-Photon Polymerization of Hydrogels Based on BSA and Carbon Nanotubes with Eosin-Y

Currently, tissue engineering technologies are promising for the restoration of damaged organs and tissues. For regeneration of electrically conductive tissues or neural interfaces, it is necessary to provide electrical conductivity for the transmission of electrophysiological signals. The developed biocomposite structures presented in this article possess such properties. Their composition includes bovine serum albumin (BSA), gelatin, eosin-Y and single-walled carbon nanotubes (SWCNTs). For the first time, a biocomposite structure was formed from the proposed hydrogel using a nanosecond laser, and a two-photon absorption cross section value of 580 GM was achieved. Increased viscosity over 3 mPa∙s and self-focusing with a nonlinear refractive index of 42 × 10-12 cm2/W make it possible to create a biocomposite structure over the entire specified area. The obtained electrical conductivity value was 19 mS∙cm-1, due to the formation of effective electrically conductive networks. For a biocomposite with a concentration of gelatin 3 wt. %, formed by low-energy near-IR pulses, the survival of Neuro 2A nerve tissue cells was confirmed. The obtained results are important for the creation of new tissue engineering structures and neural interfaces from a biopolymer hydrogel based on the organic dye eosin-Y and carbon nanotubes by two-photon polymerization.

Push-Pull Carbazole-Based Dyes: Synthesis, Strong Ultrafast Nonlinear Optical Response, and Effective Photoinitiation for Multiphoton Lithography

The present work reports on the ultrafast nonlinear optical (NLO) properties of a series of D-π-Α and D-A push-pull carbazole-based dyes and establishes a correlation between these properties and their efficiency for potential photonic and optoelectronic applications such as multiphoton lithography (MPL). The ultrafast NLO properties of the studied dyes are determined by two distinct experimental techniques, Z-scan and pump-probe optical Kerr effect (OKE), employing 246 fs laser pulses at 515 nm. The results indicate that chemical functionalization of the carbazole moiety with various strong electron-donating and/or electron-withdrawing groups, such as benzene, styrene, 4-bromostyrene, nitrobenzene, trimethyl isocyanurate, methyl, and indane-1,3-dione, can result in a controlled and significant enhancement of the NLO absorptive and refractive responses. In the context of potential applications, the efficiency of carbazole-based organic materials as photoinitiators (PIs) for MPL applications is demonstrated. The fabricated woodpile microstructure using chemically functionalized carbazole as a PI demonstrates improvements in both feature size and MPL efficiency compared to that using unfunctionalized carbazole as a PI. This is attributed to the efficient charge transfer resulting from chemical functionalization, which leads to a substantial increase (approximately 1 order of magnitude) in the values of the imaginary part of the second-order hyperpolarizability (Imγ) and the two-photon absorption cross section (σ). The achieved feature size of 280 nm is comparable to that obtained with other widely used PIs in MPL applications. Additionally, owing to the strong NLO properties of the studied functionalized carbazole, they could also be promising candidates for further applications in photonics and optoelectronics.

Recent Developments in Bio-Ink Formulations Using Marine-Derived Biomaterials for Three-Dimensional (3D) Bioprinting

3D bioprinting is a disruptive, computer-aided, and additive manufacturing technology that allows the obtention, layer-by-layer, of 3D complex structures. This technology is believed to offer tremendous opportunities in several fields including biomedical, pharmaceutical, and food industries. Several bioprinting processes and bio-ink materials have emerged recently. However, there is still a pressing need to develop low-cost sustainable bio-ink materials with superior qualities (excellent mechanical, viscoelastic and thermal properties, biocompatibility, and biodegradability). Marine-derived biomaterials, including polysaccharides and proteins, represent a viable and renewable source for bio-ink formulations. Therefore, the focus of this review centers around the use of marine-derived biomaterials in the formulations of bio-ink. It starts with a general overview of 3D bioprinting processes followed by a description of the most commonly used marine-derived biomaterials for 3D bioprinting, with a special attention paid to chitosan, glycosaminoglycans, alginate, carrageenan, collagen, and gelatin. The challenges facing the application of marine-derived biomaterials in 3D bioprinting within the biomedical and pharmaceutical fields along with future directions are also discussed.

High-Throughput Two-Photon 3D Printing Enabled by Holographic Multi-Foci High-Speed Scanning

The emerging two-photon polymerization (TPP) technique enables high-resolution printing of complex 3D structures, revolutionizing micro/nano additive manufacturing. Various fast scanning and parallel processing strategies have been proposed to promote its efficiency. However, obtaining large numbers of uniform focal spots for parallel high-speed scanning remains challenging, which hampers the realization of higher throughput. We report a TPP printing platform that combines galvanometric mirrors and liquid crystal on silicon spatial light modulator (LCoS-SLM). By setting the target light field at LCoS-SLM's diffraction center, sufficient energy is acquired to support simultaneous polymerization of over 400 foci. With fast scanning, the maximum printing speed achieves 1.49 × 108 voxels s-1, surpassing the existing scanning-based TPP methods while maintaining high printing resolution and flexibility. To demonstrate the processing capability, functional 3D microstructure arrays are rapidly fabricated and applied in micro-optics and micro-object manipulation. Our method may expand the prospects of TPP in large-scale micro/nanomanufacturing.

Light Sheet-Based Laser Patterning Bioprinting Produces Long-Term Viable Full-Thickness Skin Constructs

Tissue engineering holds great promise for biomedical research and healthcare, offering alternatives to animal models and enabling tissue regeneration and organ transplantation. 3D bioprinting stands out for its design flexibility and reproducibility. Here, an integrated fluorescent light sheet bioprinting and imaging system is presented that combines high printing speed (0.66 mm3 /s) and resolution (9 µm) with light sheet-based imaging. This approach employs direct laser patterning and a static light sheet for confined voxel crosslinking in photocrosslinkable materials. The developed bioprinter enables real-time monitoring of hydrogel crosslinking using fluorescent recovery after photobleaching (FRAP) and brightfield imaging as well as in situ light sheet imaging of cells. Human fibroblasts encapsulated in a thiol-ene click chemistry-based hydrogel exhibited high viability (83% ± 4.34%) and functionality. Furthermore, full-thickness skin constructs displayed characteristics of both epidermal and dermal layers and remained viable for 41 days. The integrated approach demonstrates the capabilities of light sheet bioprinting, offering high speed, resolution, and real-time characterization. Future enhancements involving solid-state laser scanning devices such as acousto-optic deflectors and modulators will further enhance resolution and speed, opening new opportunities in light-based bioprinting and advancing tissue engineering.

Hydrogels and Bioprinting in Bone Tissue Engineering: Creating Artificial Stem-Cell Niches for In Vitro Models

Advances in bioprinting have enabled the fabrication of complex tissue constructs with high speed and resolution. However, there remains significant structural and biological complexity within tissues that bioprinting is unable to recapitulate. Bone, for example, has a hierarchical organization ranging from the molecular to whole organ level. Current bioprinting techniques and the materials employed have imposed limits on the scale, speed, and resolution that can be achieved, rendering the technique unable to reproduce the structural hierarchies and cell-matrix interactions that are observed in bone. The shift toward biomimetic approaches in bone tissue engineering, where hydrogels provide biophysical and biochemical cues to encapsulated cells, is a promising approach to enhancing the biological function and development of tissues for in vitro modeling. A major focus in bioprinting of bone tissue for in vitro modeling is creating dynamic microenvironmental niches to support, stimulate, and direct the cellular processes for bone formation and remodeling. Hydrogels are ideal materials for imitating the extracellular matrix since they can be engineered to present various cues whilst allowing bioprinting. Here, recent advances in hydrogels and 3D bioprinting toward creating a microenvironmental niche that is conducive to tissue engineering of in vitro models of bone are reviewed.

Use of 3D Printing Techniques to Fabricate Implantable Microelectrodes for Electrochemical Detection of Biomarkers in the Early Diagnosis of Cardiovascular and Neurodegenerative Diseases

This Review provides a comprehensive overview of 3D printing techniques to fabricate implantable microelectrodes for the electrochemical detection of biomarkers in the early diagnosis of cardiovascular and neurodegenerative diseases. Early diagnosis of these diseases is crucial to improving patient outcomes and reducing healthcare systems' burden. Biomarkers serve as measurable indicators of these diseases, and implantable microelectrodes offer a promising tool for their electrochemical detection. Here, we discuss various 3D printing techniques, including stereolithography (SLA), digital light processing (DLP), fused deposition modeling (FDM), selective laser sintering (SLS), and two-photon polymerization (2PP), highlighting their advantages and limitations in microelectrode fabrication. We also explore the materials used in constructing implantable microelectrodes, emphasizing their biocompatibility and biodegradation properties. The principles of electrochemical detection and the types of sensors utilized are examined, with a focus on their applications in detecting biomarkers for cardiovascular and neurodegenerative diseases. Finally, we address the current challenges and future perspectives in the field of 3D-printed implantable microelectrodes, emphasizing their potential for improving early diagnosis and personalized treatment strategies.

3D nanopolymerization and damage threshold dependence on laser wavelength and pulse duration

The dependence of the polymerization and optical damage thresholds in multi-photon polymerization (MPP) lithography was studied using a broadly-tunable laser system with group delay dispersion (GDD) control. The order of non-linearity and the light-matter interaction mechanisms were investigated using the resolution bridges method for non-photosensitized SZ2080TM and photosensitized SZ2080TM + IRG369 prepolymers. Energy deposition, voxel dimension growth, and the size of the dynamic fabrication window (DFW) were measured in the 700-1300 nm wavelength range at three different pulse durations measured at the sample - 100, 200 and 300 fs. Polymerization was observed at all wavelengths and pulse durations without significant differences in the achieved minimal spatial dimension ( < 300 nm). This was achieved despite the broad range of excitation wavelengths used which spanned two- and three-photon absorption bands, and the differences in the absorption spectra of the prepolymers. The lateral and longitudinal voxel growth dynamics revealed an abrupt change in the power dependence of polymerization and a significant variation of the DFW - from 1 at 1250 nm to 29 at 700 nm. This result can be interpreted as a consequence of a change in the instantaneous refractive index and a lowering of the polymerization but not the damage threshold. The optimization of energy delivery to the material by a wavelength-tunable laser source with pulse duration control was experimentally validated. These findings are uncovering the complexity of polymerization mechanisms and are useful in further development of MPP technology.

Two-Photon Polymerization: Fundamentals, Materials, and Chemical Modification Strategies

Two-photon polymerization (TPP) has become a premier state-of-the-art method for microscale fabrication of bespoke polymeric devices and surfaces. With applications ranging from the production of optical, drug delivery, tissue engineering, and microfluidic devices, TPP has grown immensely in the past two decades. Significantly, the field has expanded from standard acrylate- and epoxy-based photoresists to custom formulated monomers designed to change the hydrophilicity, surface chemistry, mechanical properties, and more of the resulting structures. This review explains the essentials of TPP, from its initial conception through to standard operating principles and advanced chemical modification strategies for TPP materials. At the outset, the fundamental chemistries of radical and cationic polymerization are described, along with strategies used to tailor mechanical and functional properties. This review then describes TPP systems and introduces an array of commonly used photoresists including hard polyacrylic resins, soft hydrogel acrylic esters, epoxides, and organic/inorganic hybrid materials. Specific examples of each class-including chemically modified photoresists-are described to inform the understanding of their applications to the fields of tissue-engineering scaffolds, micromedical, optical, and drug delivery devices.

Mechanical property of pixel extrusion and pin forming for polymer, ceramic, and metal formation

The rapid material fabrications in pixel shape were mechanically studied in comparison with FDM and STL 3D printing technique. The pixel extrusion technique was the extrusion with a set of holes in the die. By controlling the flow of each hole in the die, the shape could be adjustable. The pixel molding technique composed of a set of pins. By adjusting the length of pin inside the mold, the shape of cavity could be designed. Compared to 3D printing which requires the material deposition with 2D scanning for several layers, 3D material fabrication by pixel extrusion and pixel molding were much faster; however, their resolutions were still much worse compared to 3D printing at the moment. SEM, Tensile test, flexural test, including hardness were used to observe the properties of pixel extrusion and pixel molding. The pixel molding technique was also used to fabricate many materials to compare the properties such as cement, iron, and silica. Apparently, materials could be formed and mechanical properties were investigated.

Nanomaterial-Embedded DNA Films on 2D Frames

Recently, 3D printing has provided opportunities for designing complex structures with ease. These printed structures can serve as molds for complex materials such as DNA and cetyltrimethylammonium chloride (CTMA)-modified DNA that have easily tunable functionalities via the embedding of various nanomaterials such as ions, nanoparticles, fluorophores, and proteins. Herein, we develop a simple and efficient method for constructing DNA flat and curved films containing water-soluble/thermochromatic dyes and di/trivalent ions and CTMA-modified DNA films embedded with organic light-emitting molecules (OLEM) with the aid of 2D/3D frames made by a 3D printer. We study the Raman spectra, current, and resistance of Cu²⁺-doped and Tb³⁺-doped DNA films and the photoluminescence of OLEM-embedded CTMA-modified DNA films to better understand the optoelectric characteristics of the samples. Compared to pristine DNA, ion-doped DNA films show noticeable variation of Raman peak intensities, which might be due to the interaction between the ion and phosphate backbone of DNA and the intercalation of ions in DNA base pairs. As expected, ion-doped DNA films show an increase of current with an increase in bias voltage. Because of the presence of metallic ions, DNA films with embedded ions showed relatively larger current than pristine DNA. The photoluminescent emission peaks of CTMA-modified DNA films with OLEM_Red, OLEM_Green, and OLEM_Blue were obtained at the wavelengths of 610, 515, and 469 nm, respectively. Finally, CIE color coordinates produced from CTMA-modified DNA films with different OLEM color types were plotted in color space. It may be feasible to produce multilayered DNA films as well. If so, multilayered DNA films embedded with different color dyes, ions, fluorescent materials, nanoparticles, proteins, and drug molecules could be used to realize multifunctional physical devices such as energy harvesting and chemo-bio sensors in the near future.

A Hydrophobic Derivative of Ciprofloxacin as a New Photoinitiator of Two-Photon Polymerization: Synthesis and Usage for the Formation of Biocompatible Polylactide-Based 3D Scaffolds

A hydrophobic derivative of ciprofloxacin, hexanoylated ciprofloxacin (CPF-hex), has been used as a photoinitiator (PI) for two-photon polymerization (2PP) for the first time. We present, here, the synthesis of CPF-hex and its application for 2PP of methacrylate-terminated star-shaped poly (D,L-lactide), as well a systematic study on the optical, physicochemical and mechanical properties of the photocurable resin and prepared three-dimensional scaffolds. CPF-hex exhibited good solubility in the photocurable resin, high absorption at the two-photon wavelength and a low fluorescence quantum yield = 0.079. Structuring tests showed a relatively broad processing window and revealed the efficiency of CPF-hex as a 2PP PI. The prepared three-dimensional scaffolds showed good thermal stability; thermal decomposition was observed only at 314 °C. In addition, they demonstrated an increase in Young's modulus after the UV post-curing (from 336 ± 79 MPa to 564 ± 183 MPa, which is close to those of a cancellous (trabecular) bone). Moreover, using CPF-hex as a 2PP PI did not compromise the scaffolds' low cytotoxicity, thus they are suitable for potential application in bone tissue regeneration.

Two-photon polymerization with diode lasers emitting ultrashort pulses with high repetition rate

In this Letter, we investigate the resolution of two-photon polymerization (2PP) with an amplified mode-locked external cavity diode laser with adjustable pulse length and a high repetition rate. The experimental results are analyzed with a newly developed 2PP model. Even with low pulse peak intensity, the produced structural dimensions are comparable to those generated by traditional 2PP laser sources. Thus, we show that a compact monolithic picosecond laser diode without amplification and with a repetition rate in the GHz regime can also be applied for 2PP. These results show the high application potential of compact mode-locked diode lasers for low-cost and compact 2PP systems.

Toward Near-Perfect Diffractive Optical Elements via Nanoscale 3D Printing

Diffractive optical elements (DOEs) are widely applied as compact solutions to generate desired optical patterns in the far field by wavefront shaping. They consist of microscopic structures of varying heights to control the phase of either reflected or transmitted light. However, traditional methods to achieve varying thicknesses of structures for DOEs are tedious, requiring multiple aligned lithographic steps each followed by an etching process. Additionally, the reliance on photomasks precludes rapid prototyping and customization in manufacturing complex and multifunctional surface profiles. To achieve this, we turn to nanoscale 3D printing based on two-photon polymerization lithography (TPL). However, TPL systems lack the precision to pattern diffractive components where subwavelength variations in height and position could lead to observable loss in diffraction efficiency. Here, we employed a lumped TPL parametric model and a workaround patterning strategy to achieve precise 3D printing of DOEs using optimized parameters for laser power, beam scan speed, hatching distance, and slicing distance. In our case study, millimeter scale near-perfect Dammann gratings were fabricated with measured diffraction efficiencies near theoretical limits, laser spot array nonuniformity as low as 1.4%, and power ratio of the zero-order spot as low as 0.4%. Leveraging on the advantages of additive manufacturing inherent to TPL, the 3D-printed optical devices can be applied for precise wavefront shaping, with great potential in all-optical machine learning, virtual reality, motion sensing, and medical imaging.

Materials and technical innovations in 3D printing in biomedical applications

3D printing is a rapidly growing research area, which significantly contributes to major innovations in various fields of engineering, science, and medicine. Although the scientific advancement of 3D printing technologies has enabled the development of complex geometries, there is still an increasing demand for innovative 3D printing techniques and materials to address the challenges in building speed and accuracy, surface finish, stability, and functionality. In this review, we introduce and review the recent developments in novel materials and 3D printing techniques to address the needs of the conventional 3D printing methodologies, especially in biomedical applications, such as printing speed, cell growth feasibility, and complex shape achievement. A comparative study of these materials and technologies with respect to the 3D printing parameters will be provided for selecting a suitable application-based 3D printing methodology. Discussion of the prospects of 3D printing materials and technologies will be finally covered.