Cell‐Laden Hydrogels for Multikingdom 3D Printing

Living materials are created through the embedding of live, whole cells into a matrix that can house and sustain the viability of the encapsulated cells. Through the immobilization of these cells, their bioactivity can be harnessed for applications such as bioreactors for the production of high‐value chemicals. While the interest in living materials is growing, many existing materials lack robust structure and are difficult to pattern. Furthermore, many living materials employ only one type of microorganism, or microbial consortia with little control over the arrangement of the various cell types. In this work, a Pluronic F127‐based hydrogel system is characterized for the encapsulation of algae, yeast, and bacteria to create living materials. This hydrogel system is also demonstrated to be an excellent material for additive manufacturing in the form of direct write 3D‐printing to spatially arrange the cells within a single printed construct. These living materials allow for the development of incredibly complex, immobilized consortia, and the results detailed herein further enhance the understanding of how cells behave within living material matrices. The utilization of these materials allows for interesting applications of multikingdom microbial cultures in immobilized bioreactor or biosensing technologies.     

Extrusion 3D printing of conjugated polymers

Conjugated polymers combine electronic charge transport properties with the ability to transport ions, enabling transduction between ionic and electronic currents. Many applications of conjugated polymers, such as biointerfaces, actuators, and energy storage, benefit from 3D structures. Among different methods for 3D fabrication, extrusion-based 3D printing is a versatile approach that is compatible with multimaterial fabrication processes. This review summarizes progress in the emerging field of 3D printed conjugated polymers using three extrusion printing processes: direct ink write, meniscus-guided printing, and electrohydrodynamic printing. Ink designs for direct in write are described in depth, including strategies for modifying the rheology and conductivity of the inks.     

A Stereolithography‐Based 3D Printed Hybrid Scaffold for In Situ Cartilage Defect Repair

Damage to articular cartilage can over time cause degeneration to the tissue surrounding the injury. To address this problem, scaffolds that prevent degeneration and promote neotissue growth are needed. A new hybrid scaffold that combines a stereolithography‐based 3D printed support structure with an injectable and photopolymerizable hydrogel for delivering cells to treat focal chondral defects is introduced. In this proof of concept study, the ability to a) infill the support structure with an injectable hydrogel precursor solution, b) incorporate cartilage cells during infilling using a degradable hydrogel that promotes neotissue deposition, and c) minimize damage to the surrounding cartilage when the hybrid scaffold is placed in situ in a focal chondral defect in an osteochondral plug that is cultured under mechanical loading is demonstrated. With the ability to independently control the properties of the structure and the injectable hydrogel, this hybrid scaffold approach holds promise for treating chondral defects.     

Wet 3‐D printing of epoxy cross‐linked chitosan/carbon microtube composite

Over the last decays, the use of conductive biopolymer composites has been growing in areas such as biosensors, soft robotics, and wound dressing applications. They are generally soft hydrophilic materials with good elastic recovery and compatible with biological environments. However, their application and removal from the host are still challenging mainly due to poor mechanical strength. This work displays a technique for the fabrication of complex‐shaped conductive structures with improved mechanical strength by wet three‐dimensional (3‐D) printing, which uses a coagulation bath to quickly solidify an epoxy cross‐linked chitosan/carbon microtube composite ink. The fabricated conductive structure demonstrated higher elongation strength and improved elastic stability upon the introducing of polypropylene glycol diglycidyl ether (PPGDGE) as the epoxy cross‐linker, which can be due to the formation of networks between oxiran groups of PPGDGE and chitosan amino groups.     

Structure and properties of polyethylene prepared via low‐frequency vibration‐assisted injection molding

A self‐made low‐frequency vibration‐assisted injection‐molding (VAIM) device was adopted to explore the relationship between mechanical property and morphology for high‐density polyethylene injected moldings. The main processing variables for the VAIM are vibration frequency and vibration pressure amplitude, and tensile properties and morphology were investigated under different VAIM processing conditions with conventional injection molding for comparison. The moldings prepared by VAIM exhibit a very well defined laminated morphology composed of a layered structure with enhanced crystallinity. Increased with vibration frequency at constant vibration pressure amplitude, the shish‐kebab structure is exhibited in the shear layer of the specimen prepared by VAIM, whereas row nucleation lamella exists in the same layer produced by enhanced vibration pressure amplitude at a constant vibration frequency. These oriented structures and enhanced crystallinity, confirmed by scanning electron microscopy, wide‐angle X‐ray diffraction, and differential scanning calorimetry, serve to obtain stronger injection moldings. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 13–21, 2005     

Curcumin‐loaded biodegradable polyurethane scaffolds modified with gelatin using 3D printing technology for cartilage tissue engineering

We described the curcumin‐loaded biodegradable polyurethane (PU) scaffolds modified with gelatin based on three‐dimensional (3D) printing technology for potential application of cartilage regeneration. The printing solution of poly(ε‐caprolactone) (PCL) triol (polyol) and hexamethylene diisocyanate (HMDI) in 2,2,2‐trifluoroethanol was printed through a nozzle in dimethyl sulfoxide phase with or without gelatin. The weight ratio of HMDI against PCL triol was varied as 3, 5, and 7 in order to evaluate its effect on the mechanical properties and biodegradation rate. A higher ratio of HMDI resulted in higher mechanical properties and a lower biodegradation rate. The use of gelatin increased the mechanical properties, biodegradation rate, and curcumin release due to the surface cross‐linking, nanoporous structure, and surface hydrophilicity of the scaffolds. In vitro study revealed that the released curcumin enhanced the proliferation and differentiation of chondrocyte. The 3D‐printed biodegradable PU scaffold modified with gelatin should thus be considered as a potential candidate for cartilage regeneration.     

Evaluation of 3D Printed Gelatin‐Based Scaffolds with Varying Pore Size for MSC‐Based Adipose Tissue Engineering

Adipose tissue engineering aims to provide solutions to patients who require tissue reconstruction following mastectomies or other soft tissue trauma. Mesenchymal stromal cells (MSCs) robustly differentiate into the adipogenic lineage and are attractive candidates for adipose tissue engineering. This work investigates whether pore size modulates adipogenic differentiation of MSCs toward identifying optimal scaffold pore size and whether pore size modulates spatial infiltration of adipogenically differentiated cells. To assess this, extrusion‐based 3D printing is used to fabricate photo‐crosslinkable gelatin‐based scaffolds with pore sizes in the range of 200–600 µm. The adipogenic differentiation of MSCs seeded onto these scaffolds is evaluated and robust lipid droplet formation is observed across all scaffold groups as early as after day 6 of culture. Expression of adipogenic genes on scaffolds increases significantly over time, compared to TCP controls. Furthermore, it is found that the spatial distribution of cells is dependent on the scaffold pore size, with larger pores leading to a more uniform spatial distribution of adipogenically differentiated cells. Overall, these data provide first insights into the role of scaffold pore size on MSC‐based adipogenic differentiation and contribute toward the rational design of biomaterials for adipose tissue engineering in 3D volumetric spaces.     

Polymer 4D printing: Advanced shape-change and beyond

4D printing is an exciting branch of additive manufacturing. It relies on established 3D printing techniques to fabricate objects in much the same way. However, structures which fall into the 4D printed category have the ability to change with time, hence the “extra dimension.” The common perception of 4D printed objects is that of macroscopic single-material structures limited to point-to-point shape change only, in response to either heat or water. However, in the area of polymer 4D printing, recent advancements challenge this understanding. A host of new polymeric materials have been designed which display a variety of wonderful effects brought about by unconventional stimuli, and advanced additive manufacturing techniques have been developed to accommodate them. As a result, the horizons of polymer 4D printing have been broadened beyond what was initially thought possible. In this review, we showcase the many studies which evolve the very definition of polymer 4D printing, and reveal emerging areas of research integral to its advancement.     

Polycaprolactone solution–based ink for designing microfluidic channels on paper via 3D printing platform for biosensing application

This work reports a novel fabrication technique for development of channels on paper‐based microfluidic devices using the syringe module of a 3D printing syringe–based system. In this study, printing using polycaprolactone (PCL)‐based ink (Mw 70 000‐90 000) was employed for the generation of functional hydrophobic barriers on Whatman qualitative filter paper grade 1 (approximate thickness of 180 μm and pore diameter of 11 μm), which would effectively channelize fluid flow to multiple assay zones dedicated for different analyte detection on a microfluidic paper‐based analytical device (μPAD). The standardization studies reveal that a functional hydrophilic channel for sample conduction fabricated using the reported technique can be as narrow as 460.7 ± 20 μm and a functional hydrophobic barrier can be of any width with a lower limit of about 982.2 ± 142.75 μm when a minimum number of two layers of the ink is extruded onto paper. A comparison with the hydrodynamic model established for writing with ink is used to explain the width of the line printed by this system. A fluid flow analysis through a single channel system was also carried out to establish its conformity with the Washburn model, which governs the fluid flow in two‐dimensional μPAD. The presented fabrication technique proves to be a robust strategy that effectively taps the advantages of this 3D printing technique in the production of μPADs with enhanced speed and reproducibility.     

3D printing of conjugated polymers

Three‐dimensional (3D) printing brings exciting prospects to the realm of conjugated polymers (CPs) and organic electronics through vastly enhanced design flexibility, structural complexity, and environmental sustainability. However, the use of 3D printing for CPs is still in its infancy and remains full of challenges. In this review, we highlight recent studies that demonstrate proof‐of‐concept strategies to mitigate some of these problems. Two general additive manufacturing approaches are featured: direct ink writing and vat photopolymerization. We conclude with an outlook for this thriving field of research and draw attention to the new possibilities that 3D printing can bring to CPs. © 2019 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2019 , 57, 1592–1605     

Three‐dimensional printing of poly(lactic acid) bio‐based composites with sugarcane bagasse fiber: Effect of printing orientation on tensile performance

The cellulose fiber was extracted from the abandoned crop sugarcane bagasse (SCB) by means of chemical treatment methods. Poly(lactic acid) (PLA) bio‐based composites with SCB were prepared through fused deposition modeling (FDM) 3D‐printing technology, and the morphologies, mechanical properties, crystallization properties, and thermal stability of 3D‐printed composites were investigated. Compared with the neat PLA, the incorporation of SCB into PLA reduces the tensile strength and flexural strength of 3D‐printed samples but increases the flexural modulus. The difference in tensile performance and bending performance is that the tensile strength of 3D‐printed samples is best when the SCB content is 6 wt%, while the flexural modulus continuously decreases as the SCB content increases. Furthermore, the effects of various printing methods on the tensile performance of 3D‐printed samples were explored via modifying G‐code of 3D models. The results indicate that the optimum SCB fiber content is identical for all printing methods except method “vertical.” Due to the fibers and molecular chains are oriented to varying degrees with altering raster angle in 3D‐printed samples, the fully oriented sample printed by method “parallel” has a better tensile strength. Besides, SCB exhibits enough high thermal decomposition temperature to meet requirements for melt extrusion processing of PLA composites, and SCB fiber is capable of promoting the crystallization of PLA.     

Keto-coumarin scaffold for photoinitiators for 3D printing and photocomposites

The purposes of this paper are moving toward (a) the development of a new series of photoinitiators (PIs) which are based on the keto-coumarin (KC) core, (b) the introduction of light-emitting diodes (LEDs) as inexpensive and safe sources of irradiation, (c) the study of the photochemical mechanisms through which the new PIs react using different techniques such as Fourier transform infrared, UV–visible or fluorescence spectroscopy, and so on, (d) the use of such compounds (presenting good reactivity and excellent photopolymerization initiating abilities) for two specific and high added value applications: 3D printing (@405 nm) and preparation of thick glass fiber photocomposites with excellent depth of cure, and finally (e) the comparison of the performance of these KC derivatives versus other synthesized coumarin derivatives. In this study, six well-designed KC derivatives ( KC-C , KC-D , KC-E , KC-F , KC-G , and KC-H ) are examined as high-performance visible-light PIs for the cationic polymerization of epoxides as well as the free-radical polymerization of acrylates upon irradiation with LED@405 nm. Excellent polymerization rates are obtained using two different approaches: a photo-oxidation process in combination with an iodonium (Iod) salt and a photo-reduction process when associated with an amine (N-phenylglycine or ethyl 4-(dimethylamino)benzoate). High final reactive conversions were obtained. A full picture of the involved photochemical mechanisms is provided.     

All‐in‐One Cellulose Nanocrystals for 3D Printing of Nanocomposite Hydrogels

Cellulose nanocrystals (CNCs) with >2000 photoactive groups on each can act as highly efficient initiators for radical polymerizations, cross‐linkers, as well as covalently embedded nanofillers for nanocomposite hydrogels. This is achieved by a simple and reliable method for surface modification of CNCs with a photoactive bis(acyl)phosphane oxide derivative. Shape‐persistent and free‐standing 3D structured objects were printed with a mono‐functional methacrylate, showing a superior swelling capacity and improved mechanical properties.     

3D printing for aqueous and non-aqueous redox flow batteries

Additive manufacturing technologies, generally grouped under the name of 3D printing, are experiencing an explosion of interest during the last few years. The possibility of fast prototyping enabled by 3D printing has been recognized as a crucial booster for device fabrication and general scientific advancements. In this review, attention is focused on the latest developments in the field of redox flow batteries which are, similar to other energy related devices, characterized by the recent adoption of 3D printing methods for the fabrication of key components. Whether simply to investigate flow phenomena, test new designs or fabricate final-product components with custom features, the use of 3D printing can critically drive this field of research towards better performing energy-storage systems. The latest and most representative examples of redox flow battery studies will be discussed, categorized in relation to the electrolyte used and whether the devices are employed in aqueous or non-aqueous applications.     

Morphological comparison of isotactic polypropylene parts prepared by micro‐injection molding and conventional injection molding

The morphological feature of microparts evolved during micro‐injection molding may differ from that of the macroparts prepared by conventional injection molding, resulting in specific physical properties. In this study, isotactic polypropylene (iPP) microparts with 200 µm thickness and macroparts with 2000 µm thickness were prepared, and their morphological comparison was investigated by means of polarized light microscopy (PLM), scanning electron microscopy (SEM), differential scanning calorimeter (DSC), and wide‐angle X‐ray diffraction (WAXD). The results presented some similarities and differences. PLM observations showed that the through‐the thickness‐morphology of micropart exhibited a similar “skin–core” structure as macropart, but presented a large fraction of shear layer in comparison to the macropart which presented a large fraction of core layer. The SEM observation of shear layer of micropart featured highly oriented shish‐kebab structure. The micropart had a more homogeneous distribution of lamellae thickness. The degree of crystallinity of the micropart was found to be higher than that of the macropart. High content of β‐crystal was found in micropart. The 2D WAXD pattern of the core layer of macropart showed full Debye rings indicating a random orientation, while the arcing of the shear layer indicates a pronounced orientation. The most pronounced arcing of the micropart indicates the most pronounced orientation of iPP chains within lamellae. Copyright © 2011 John Wiley & Sons, Ltd.     

High transmission 3D printed flex‐PCB‐based ion funnel

In this study a novel fabrication method for a radio frequency (RF) ion funnel is presented. RF ion funnels are important devices for focusing ion clouds at low vacuum conditions for mass spectrometry or deposition‐related applications. Typically, ion funnels are constructed of stainless steel plate ring electrodes with a decreasing diameter where RF and direct current potentials are applied to the electrodes to focus the ion cloud. The presented novel design is based on a flexible circuit board that serves both as the signal distribution circuit and as the electrodes of the ion funnel. The flexible circuit board is rolled into a 3D printed scaffold to create a funnel shape with ring electrodes formed by the copper electrodes of the flexible circuit board. The design is characterized in direct comparison with a conventional steel‐plate electrode design. The discussed results show that the new funnel has similar performance to the conventionally designed funnel despite much lower manufacturing costs. Copyright © 2015 John Wiley & Sons, Ltd.     

On‐Demand Production of Flow‐Reactor Cartridges by 3D Printing of Thermostable Enzymes

The compartmentalization of chemical reactions is an essential principle of life that provides a major source of innovation for the development of novel approaches in biocatalysis. To implement spatially controlled biotransformations, rapid manufacturing methods are needed for the production of biocatalysts that can be applied in flow systems. Whereas three‐dimensional (3D) printing techniques offer high‐throughput manufacturing capability, they are usually not compatible with the delicate nature of enzymes, which call for physiological processing parameters. We herein demonstrate the utility of thermostable enzymes in the generation of biocatalytic agarose‐based inks for a simple temperature‐controlled 3D printing process. As examples we utilized an esterase and an alcohol dehydrogenase from thermophilic organisms as well as a decarboxylase that was thermostabilized by directed protein evolution. We used the resulting 3D‐printed parts for a continuous, two‐step sequential biotransformation in a fluidic setup.     

Miniaturized free-flow electrophoresis: production,optimization, and application using 3D printing technology

The increasing resolution of three-dimensional (3D) printing offers simplified access to, and development of, microfluidic devices with complex 3D structures. Therefore, this technology is increasingly used for rapid prototyping in laboratories and industry. Microfluidic free flow electrophoresis (μFFE) is a versatile tool to separate and concentrate different samples (such as DNA, proteins, and cells) to different outlets in a time range measured in mere tens of seconds and offers great potential for use in downstream processing, for example. However, the production of μFFE devices is usually rather elaborate. Many designs are based on chemical pretreatment or manual alignment for the setup. Especially for the separation chamber of a μFFE device, this is a crucial step which should be automatized. We have developed a smart 3D design of a μFFE to pave the way for a simpler production. This study presents (1) a robust and reproducible way to build up critical parts of a μFFE device based on high-resolution MultiJet 3D printing; (2) a simplified insertion of commercial polycarbonate membranes to segregate separation and electrode chambers; and (3) integrated, 3D-printed wells that enable a defined sample fractionation (chip-to-world interface). In proof of concept experiments both a mixture of fluorescence dyes and a mixture of amino acids were successfully separated in our 3D-printed μFFE device.