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Abstract Microneedle arrays show many advantages in drug delivery applications due to their convenience and reduced risk of infection. Compared to other microscale manufacturing methods, 3D printing easily overcomes challenges in the fabrication of microneedles with complex geometric shapes and multifunctional performance. However, due to material characteristics and limitations on printing capability, there are still bottlenecks to overcome for 3D printed microneedles to achieve the mechanical performance needed for various clinical applications. The hierarchical structures in limpet teeth, which are extraordinarily strong, result from aligned fibers of mineralized tissue and protein‐based polymer reinforced frameworks. These structures provide design inspiration for mechanically reinforced biomedical microneedles. Here, a bioinspired microneedle array is fabricated using magnetic field‐assisted 3D printing (MF‐3DP). Micro‐bundles of aligned iron oxide nanoparticles (aIOs) are encapsulated by polymer matrix during the printing process. A bioinspired 3D‐printed painless microneedle array is fabricated, and suitability of this microneedle patch for drug delivery during long‐term wear is demonstrated. The results reported here provide insights into how the geometrical morphology of microneedles can be optimized for the painless drug delivery in clinical trials. 

Abstract Flexible sensors with accurate detection of environmental stimuli (e.g., humidity and chemical substances) have drawn increasing research interests in biomedical engineering and environmental science. However, most work is focused on isotropic sensing of liquid occurrence due to the limitation of material development, sensor design, and fabrication capability. 3D printing is used to build multifunctional flexible liquid sensors with multimaterials enabling anisotropic detection of microliquid droplets, and described herein. Electrical conductive composite hydrogels capable of detecting chemical liquid are developed with poly (ethylene diacrylate) (PEGDA) and multiwalled carbon nanotube (MWCNT). Due to the absorption of the liquid droplet and related swelling behavior, the resistance of PEGDA/MWCNT composite hydrogel increases dramatically, while the resistance of pure PEGDA hydrogel decreases significantly. Based on the two composite hydrogels and the related 3D printing method, a mesh‐shaped liquid sensor that can effectively identify the position and volume of liquid leakage in a short time is developed. Furthermore, a three‐layered liquid sensor to enable bidirectional monitor and detection of the liquid leakage in two different sides is demonstrated. The 3D‐printed liquid sensor offers a distinctive perspective on the potential applications in various fields for detection of liquid leakage in accurate position and direction. 

The revolution of additive manufacturing (AM) has led to many opportunities in fabricating complex and novel products. The increase of printable materials and the emergence of novel fabrication processes continuously expand the possibility of engineering systems in which product components are no longer limited to be single material, single scale, or single function. In fact, a paradigm shift is taking place in industry from geometry-centered usage to supporting functional demands. Consequently, engineers are expected to resolve a wide range of complex and difficult problems related to functional design. Although a higher degree of design freedom beyond geometry has been enabled by AM, there are only very few computational design approaches in this new AM-enabled domain to design objects with tailored properties and functions. The objectives of this review paper are to provide an overview of recent additive manufacturing developments and current computer-aided design methodologies that can be applied to multimaterial, multiscale, multiform, and multifunctional AM technologies. The difficulties encountered in the computational design approaches are summarized and the future development needs are emphasized. In the paper, some present applications and future trends related to additive manufacturing technologies are also discussed.