Ceramic Robocasting: Recent Achievements, Potential, and Future Developments

Effect of Foreign Ion Substitution and Micropore Tuning in Robocasting Single-Phase Bioceramic Scaffolds on the Physicochemical Property and Vascularization

The inorganic powder slurry extrusion printing technique known as robocasting is an interesting method to fabricate complex porous architectures whereby feedstocks containing organic binders and powders are printed and the resulting scaffolds are subjected to sintering. A major limiting factor of this technique is the simultaneous tailoring of vascularization efficacy and osteogenic activity, usually done by adding the secondary phase in the organic slurry before the writing step. Mechanical mixing of biphasic powders is required to avoid compromising the biological performance and physical defects caused by significantly different physicochemical properties. This study addresses this issue by developing a selective ion doping and microstructure tuning for the production of bioceramic scaffolds with a binozzle robocasting process. Different metal ions (Sr²⁺, Mg²⁺) were doped into wollastonite (CaSiO₃; CSi) powders considering the mechanical stability and bioactive enhancement of the bioceramic scaffolds. Subsequently, the Mg-doped CSi slurries were used as shell-nozzle feedstocks added with 5, 10, and 15 μm diameter polystyrene microbeads that allowed shell-layer micropore production in pore struts during sintering. Finally, the most promising pore-strut microstructures and mechanical evolution of scaffolds were evaluated, and especially the enhanced fibrovascularization potential was confirmed in dorsal muscle embedding model in rabbits. This study may open an avenue to designing multiproperty-tuned macro- and microporous bioceramics for bone regenerative medicine, especially in challenging bone defect conditions.

Rapid Open-Air Digital Light 3D Printing of Thermoplastic Polymer

3D printing has witnessed a new era in which highly complexed customized products become reality. Realizing its ultimate potential requires simultaneous attainment of both printing speed and product versatility. Among various printing techniques, digital light processing (DLP) stands out in its high speed but is limited to intractable light curable thermosets. Thermoplastic polymers, despite their reprocessibility that allows more options for further manipulation, are restricted to intrinsically slow printing methods such as fused deposition modeling. Extending DLP to thermoplastics is highly desirable, but is challenging due to the need to reach rapid liquid-solid separation during the printing process. Here, a successful attempt at DLP printing of thermoplastic polymers is reported, realized by controlling two competing kinetic processes (polymerization and polymer dissolution) simultaneously occurring during printing. With a selected monomer, 4-acryloylmorpholine (ACMO), printing of thermoplastic 3D scaffolds is demonstrated, which can be further converted into various materials/devices utilizing its unique water-soluble characteristic. The ultralow viscosity of ACMO, along with surface oxygen inhibition, allows rapid liquid flow toward high-speed open-air printing. The process simplicity, enabling mechanism, and material versatility broaden the scope of 3D printing in constructing functional 3D devices including reconfigurable antenna, shape-shifting structures, and microfluidics.

Multicatalysis Combining 3D-Printed Devices and Magnetic Nanoparticles in One-Pot Reactions: Steps Forward in Compartmentation and Recyclability of Catalysts

A tricatalytic compartmentalized system that immobilizes metallic species to perform one-pot sequential functionalization is described: a three-dimensional (3D)-printed palladium monolith, ferritic copper(I) magnetic nanoparticles, and a 3D-printed polypropylene capsule-containing copper(II) loaded onto polystyrene-supported 1,5,7-triazabicyclo[4.4.0]dec-5-ene (PS-TBD) allowed the rapid synthesis of diverse substituted 1-([1,1'-biphenyl]-4-yl)-1H-1,2,3-triazoles. The procedure is based on the Chan-Lam azidation/copper alkyne-azide cycloaddition/Suzuki reaction strategy in the solution phase. This catalytic system enabled the efficient assembly of the final compounds in high yields without the need for special additives or intermediate isolation. The monolithic catalyst-containing immobilized palladium species was synthesized by surface chemical modification of a 3D-printed silica monolith using a soluble polyimide resin as a key reagent, thus creating an extremely robust composite. All three immobilized catalysts described here were easily recovered and reused in numerous cycles. This work exemplifies the role of 3D printing in the design and manufacture of devices for compartmented multicatalytic systems to carry out complex one-pot transformations.

PVB/PEG-Based Feedstocks for Injection Molding of Alumina Microreactor Components

The ceramic injection molding (CIM) process is a cost-effective powder-based near net shape manufacturing process for large-scale production of complex-shaped ceramic functional components. This paper presents the rheological analysis of environmentally friendly CIM feedstock formulations based on the binder components polyvinyl butyral (PVB) and polyethylene gycol (PEG). The prepared PVB/PEG-based alumina molding compounds were investigated with respect to their PVB:PEG ratios as well as to their powder filling degrees in the range between 50 and 64 vol.%. Corresponding viscosities and shear stresses were determined for increasing shear rates to show the effects of increased PEG content and solid loadings on them. Two single reactor components were injection molded and subsequently joined in their green state for fabrication of an alumina microreactor. The intended purpose of the alumina microreactors is their potential application as wear-resistant and hydrothermal stable multifunctional devices (µ-mixer, µ-reactor, µ-analyzer) for continuous hydrothermal synthesis (CHTS) of metal oxide nanoparticles in supercritical water (sc-H₂O) as the reaction medium.

Mechano-Plastic Pyrolysis of Dynamic Covalent Polymer Network toward Hierarchical 3D Ceramics

Shaping ceramics into complex 3D geometries is desirable yet challenging, particularly those with structural hierarchy spanning different length scales. A mechano-plastic pyrolysis process that overcomes this limitation is reported. In addition to taking advantage of the moldability of organic polymers, the process uniquely incorporates mechano-plasticity via dynamic covalent bond exchange for reconfiguring the shape of a preceramic polymer. The combined steps result in simultaneous shape control at both micro- and macro-scales. Further pyrolysis leads to complex ceramic structures that are otherwise difficult to produce. To enable this process, rational design of the polymer network is required to satisfy an unusual combination of mechano-plasticity and pyrolysis. Overall, the process offers an avenue for efficient fabrication of hierarchical 3D ceramic structures suitable for engineering applications.