More Like this

1. Controlling Porosity of 3D Bioprinted Scaffold: A Process Parameter-Based Approach

   Quigley, C. ; Clark, S. ; & Habib, M. A. ( May 2023 , Proceedings of the IISE Annual Conference & Expo 2023)

   Babski-Reeves, K ; Eksioglu, B ; Hampton, D. (Ed.)

   Extrusion-based 3D bioprinting is a promising method for repairing patient-specific tissues and organs due to its inherent capacity to release biocompatible materials containing living cells in a preset area. The filament geometry and width mostly determine the scaffold architecture. Extrusion pressure, print speed, print distance, nozzle diameter, and material viscosity are just a few of the process variables that can be carefully chosen to affect the filament shape and width, ultimately verifying the user-defined scaffold porosity. To maintain defined filament width variation for various hydrogels within an acceptable range and to confirm the overall geometric fidelity of the scaffold, in this paper, filament width for a set of biomaterial compositions was determined using an image processing technique and an analytical relationship, including various process parameters, was developed. 

   more » « less
2. Process monitoring and control strategies in extrusion-based bioprinting to fabricate spatially graded structures

   AA Armstrong, A Pfeil ( April 2021 , Bioprinting)

   null (Ed.)

   Extrusion-based bioprinting is the most common printing technology used in regenerative medicine. Despite recent technological advances, a pressing challenge for extrusion printing is low spatial resolution, which limits the functionality of printed constructs. One of the reasons for the low spatial resolution is a lack of process monitoring and control strategies to monitor fabrication and correct for print errors. Few research efforts implement process control and investigate the relationship between extrusion process parameters and printing fidelity. The lack of understanding between process parameters and print results ultimately limits the complexity of the possible structures. For example, fabrication of structures whose topologies vary spatially within the part is not possible without advanced process control. Here we enable fabrication of advanced spatially graded structures by implementing process monitoring and control strategies. We develop material models to better understand the relationship between process parameters and printing outcomes. We also present an experimental procedure to generate a process map that provides insight into the regions of the processing space that produce the desired extrusion features (e.g., width of the filament). After generation of a process map and material models, we implement a process monitoring and control strategy that measures the feature error and intelligently updates the process control inputs to reduce defects and improve spatial fidelity, which will lead to better functionality of the final construct. 

   more » « less
3. Computational Modeling and Experimental Characterization of Extrusion Printing into Suspension Baths

   https://doi.org/10.1002/adhm.202101679  

   Prendergast, Margaret E. ; Burdick, Jason A. ( November 2021 , Advanced Healthcare Materials)

   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.

    

   more » « less
4. Direct Ink Write 3D Printing of Fully Dense and Functionally Graded Liquid Metal Elastomer Foams

   https://doi.org/10.1002/adfm.202410908  

   Pak, Spencer ; Bartlett, Michael_D ; Markvicka, Eric_J ( September 2024 , Advanced Functional Materials)

   Liquid metal (LM) elastomer composites offer promising potential in soft robotics, wearable electronics, and human‐machine interfaces. Direct ink write (DIW) 3D printing offers a versatile manufacturing technique capable of precise control over LM microstructures, yet challenges such as interfilament void formation in multilayer structures impact material performance. Here, a DIW strategy is introduced to control both LM microstructure and material architecture. Investigating three key process parameters–nozzle height, extrusion rate, and nondimensionalized nozzle velocity–it is found that nozzle height and velocity predominantly influence filament geometry. The nozzle height primarily dictates the aspect ratio of the filament and the formation of voids. A threshold print height based on filament geometry is identified; below the height, significant surface roughness occurs, and above the ink fractures, which facilitates the creation of porous structures with tunable stiffness and programmable LM microstructure. These porous architectures exhibit reduced density and enhanced thermal conductivity compared to cast samples. When used as a dielectric in a soft capacitive sensor, they display high sensitivity (gauge factor = 9.0), as permittivity increases with compressive strain. These results demonstrate the capability to simultaneously manipulate LM microstructure and geometric architecture in LM elastomer composites through precise control of print parameters, while maintaining geometric fidelity in the printed design.

    

   more » « less
5. Self‐Regulative Direct Ink Writing of Frontally Polymerizing Thermoset Polymers

   https://doi.org/10.1002/admt.202200230  

   Aw, Jia En ; Zhang, Xiang ; Nelson, Arif Z. ; Dean, Leon M. ; Yourdkhani, Mostafa ; Ewoldt, Randy H. ; Geubelle, Philippe H. ; Sottos, Nancy R. ( April 2022 , Advanced Materials Technologies)

   The ability to manufacture highly intricate designs is one of the key advantages of 3D printing. Achieving high dimensional accuracy requires precise, often time‐consuming calibration of the process parameters. Computerized feedback control systems for 3D printing enable sensing and real‐time adaptation and optimization of these parameters at every stage of the print, but multiple challenges remain with sensor embedment and measurement accuracy. In contrast to these active control approaches, here, the authors harness frontal polymerization (FP) to rapidly cure extruded filament in tandem with the printing process. A temperature gradient present along the filament, which is dependent on the printing parameters, can impose control over this exothermic reaction. Experiments and theory reveal a self‐regulative mechanism between filament temperature and cure kinetics that allows the frontal cure speed to autonomously match the print speed. This self‐regulative printing process rapidly adapts to changes in print speed and environmental conditions to produce complex, high‐fidelity structures and freestanding architectures spanning up to 100 mm, greatly expanding the capabilities of direct ink writing (DIW).

    

   more » « less