Microscale Electro-Hydrodynamic Cell Printing with High Viability

Extraction of type I collagen and development of collagen methacryloyl (ColMA)/PEGDA ink for digital light processing printing

The fabrication of three-dimensional (3D) biostructures through additive manufacturing relies on the critical role of ink development. With the growing demand for high-resolution manufacturing, digital light processing (DLP) technology has emerged as a promising technique requiring specialised photosensitive inks. Although gelatine methacryloyl (GelMA) has been the primary option for DLP, its mechanical properties, biocompatibility, and low stability still present limitations. The development of collagen-based ink is thus in high demand for a wider stiffness adjustment range, native bioactivities, and versatility in biomedical engineering applications. In this paper, we report a rapid and low-cost protocol for collagen methacryloyl (ColMA)/poly(ethylene glycol) diacrylate (PEGDA) ink for DLP printing. The ink demonstrated the highest printing resolution of ∼50 μm by using 405 nm visible light. The printability, mechanical properties and cell viability of the DLP-printed ColMA/PEGDA structures were comprehensively evaluated. The printed ColMA/PEGDA structures reached a compressive modulus over 100 kPa with 0.6 wt% collagen. The printed ColMA/PEGDA scaffolds promoted the attachment and proliferation of 3 T3 fibroblasts, demonstrating their potential in future applications in biomedical engineering.

High-density, high-frequency and large-scale electrohydrodynamic drop-on-demand jetting via a protruding polymer-based printhead design

Electrohydrodynamic (EHD) printing has critical merits in micro/nanoscale additive manufacturing because of its ultrahigh resolution and wide ink compatibility, making it an advantageous choice for electronics manufacturing, high-resolution prototyping, and biological component fabrication. However, EHD printing is currently limited by its rather low throughput due to the lack of high-frequency and high-density multi-nozzle printheads. This paper presents a novel EHD printhead with a protruding polymer-based nozzle design. An insulated, hydrophobic, and protruding polymer nozzle array with an appropriate geometric structure can effectively address key problems in multi-nozzle jetting, such as electrical crosstalk, electrical discharge, liquid flooding, and nonuniform jetting. By investigating the influence of the electrical and geometric characteristics of the nozzle arrays on the electrical crosstalk behavior and fabricating the optimized nozzle array via MEMS technology, we achieve an EHD printhead with a large scale (256), high density (127 dpi), and high jetting frequency (23 kHz), and addressable jetting can be realized by adding independently controllable extractors underneath the nozzle array. Many functional materials, such as quantum dots, perovskite, and nanosilver inks, can be ejected into high-resolution patterns through the optimized nozzle array, demonstrating the great prospects of our designed printhead in electronics manufacturing. This MEMS-compatible printhead design lays the foundation for high-throughput fabrication of micro/nanostructures and promotes practical applications of EHD printing in functional electronics and biomedical/energy devices.

Electrohydrodynamic Direct-Writing Micro/Nanofibrous Architectures: Principle, Materials, and Biomedical Applications

Electrohydrodynamic (EHD) direct-writing has recently gained attention as a highly promising additive manufacturing strategy for fabricating intricate micro/nanoscale architectures. This technique is particularly well-suited for mimicking the extracellular matrix (ECM) present in biological tissue, which serves a vital function in facilitating cell colonization, migration, and growth. The integration of EHD direct-writing with other techniques has been employed to enhance the biological performance of scaffolds, and significant advancements have been made in the development of tailored scaffold architectures and constituents to meet the specific requirements of various biomedical applications. Here, a comprehensive overview of EHD direct-writing is provided, including its underlying principles, demonstrated materials systems, and biomedical applications. A brief chronology of EHD direct-writing is provided, along with an examination of the observed phenomena that occur during the printing process. The impact of biomaterial selection and architectural topographic cues on biological performance is also highlighted. Finally, the major limitations associated with EHD direct-writing are discussed.

Development of Electro-Conductive Composite Bioinks for Electrohydrodynamic Bioprinting with Microscale Resolution

Bioprinting has attracted extensive attention in the field of tissue engineering due to its unique capability in constructing biomimetic tissue constructs in a highly controlled manner. However, it is still challenging to reproduce the physical and structural properties of native electroactive tissues due to the poor electroconductivity of current bioink systems as well as the limited printing resolution of conventional bioprinting techniques. In this work, an electro-conductive hydrogel is prepared by introducing poly (3,4-ethylene dioxythiophene): poly (styrene sulfonate) (PEDOT: PSS) into an RGD (GGGGRGDSP)-functionalized alginate and fibrin system (RAF), and then electrohydrodynamic (EHD)-bioprinted to form living tissue constructs with microscale resolution. The addition of 0.1 (w/v%) PEDOT: PSS increases the electroconductivity to 1.95 ± 0.21 S m-1 and simultaneously has little effect on cell viability. Compared with pure RAF bioink, the presence of PEDOT: PSS expands the printable parameters for EHD-bioprinting, and hydrogel filaments with the smallest feature size of 48.91 ± 3.44 µm can be obtained by further optimizing process parameters. Furthermore, the EHD-bioprinted electro-conductive living tissue constructs with improved resolution show good viability (>85%). The synergy of the advanced electro-conductive hydrogel and EHD-bioprinting presented here may provide a promising approach for engineering electro-conductive and cell-laden constructs for electroactive tissue engineering.

Electrospinning and Cell Fibers in Biomedical Applications

Human body tissues such as muscle, blood vessels, tendon/ligaments, and nerves have fiber-like fascicle morphologies, where ordered organization of cells and extracellular matrix (ECM) within the bundles in specific 3D manners orchestrates cells and ECM to provide tissue functions. Through engineering cell fibers (which are fibers containing living cells) as living building blocks with the help of emerging "bottom-up" biomanufacturing technologies, it is now possible to reconstitute/recreate the fiber-like fascicle morphologies and their spatiotemporally specific cell-cell/cell-ECM interactions in vitro, thereby enabling the modeling, therapy, or repair of these fibrous tissues. In this article, a concise review is provided of the "bottom-up" biomanufacturing technologies and materials usable for fabricating cell fibers, with an emphasis on electrospinning that can effectively and efficiently produce thin cell fibers and with properly designed processes, 3D cell-laden structures that mimic those of native fibrous tissues. The importance and applications of cell fibers as models, therapeutic platforms, or analogs/replacements for tissues for areas such as drug testing, cell therapy, and tissue engineering are highlighted. Challenges, in terms of biomimicry of high-order hierarchical structures and complex dynamic cellular microenvironments of native tissues, as well as opportunities for cell fibers in a myriad of biomedical applications, are discussed.

Integrated silicon microfluidic chip for picoliter-scale analyte segmentation and microscale printing for mass spectrometry imaging

A silicon single-chip microfluidics system that integrates microscale fluidic channels, an analyte segmentation device, and a nozzle for electrohydrodynamic-assisted printing is designed for hyphenation with MALDI mass spectrometry (MS) imaging. A miniaturized T-junction segments analytes into monodisperse picoliter oil-isolated compartments. The printing nozzle deposits generated droplets one-by-one into an array on a conductive substrate without splitting or coalescing. Virtually single-shot MS analysis is enabled due to the ultrasmall droplet volumes and highly localized printing. The signal-to-noise ratio indicates that detection limits at the attomole level are achieved for γ-aminobutyric acid.

Bioinspired gelatin nano-film implanted into composite scaffold exhibiting both expandable adhesion and enhanced proliferation

Tissue engineering technology provides a new treatment to the cartilage damage. Recent progress has focused on coating strategies with the printed scaffold surface, using various materials such as bioactive nanocomposites. However, the fracture and exfoliation of printed scaffolds remain challenges due to their poor adhesion on smooth substrates. These limitations can be offset by developing a versatile film. Here, inspired by the mechanism of the wet adhesion of snails, we introduced a biomimetic nanoscale gelatin film between a smooth conductive slide and a scaffold, which enhanced early cell adhesion rates through water absorption, swelling and adhesion. A bionic technique of preparing gelatin nanofilms and PVP/PCL 3D scaffolds, which involved E-Jet atomization deposition and E-Jet printing techniques based on the electrohydrodynamic effect, was investigated. It is found that the composite scaffold with 400 nm gelatin nanofilm significantly enhances cell attachment (from 62 % to 87 %) and proliferation (increased 6.5 times in 7 days). Collectively, this study highlights the combination of biomimetic nanoscale adhesive film in promoting cell adhesion and cartilage differentiation, which benefiting from water absorption and swelling of gelatin nanofilm. This work provides a new idea for the potential application in the orthopedics field.

Biomimetic and Biologically Compliant Soft Architectures via 3D and 4D Assembly Methods: A Perspective

Recent progress in soft material chemistry and enabling methods of 3D and 4D fabrication-emerging programmable material designs and associated assembly methods for the construction of complex functional structures-is highlighted. The underlying advances in this science allow the creation of soft material architectures with properties and shapes that programmably vary with time. The ability to control composition from the molecular to the macroscale is highlighted-most notably through examples that focus on biomimetic and biologically compliant soft materials. Such advances, when coupled with the ability to program material structure and properties across multiple scales via microfabrication, 3D printing, or other assembly techniques, give rise to responsive (4D) architectures. The challenges and prospects for progress in this emerging field in terms of its capacities for integrating chemistry, form, and function are described in the context of exemplary soft material systems demonstrating important but heretofore difficult-to-realize biomimetic and biologically compliant behaviors.

Embedded bioprinting for designer 3D tissue constructs with complex structural organization

3D bioprinting has been developed as an effective and powerful technique for the fabrication of living tissue constructs in a well-controlled manner. However, most existing 3D bioprinting strategies face substantial challenges in replicating delicate and intricate tissue-specific structural organizations using mechanically weak biomaterials such as hydrogels. Embedded bioprinting is an emerging bioprinting strategy that can directly fabricate complex structures derived from soft biomaterials within a supporting matrix, which shows great promise in printing large vascularized tissues and organs. Here, we provide a state-of-the-art review on the development of embedded bioprinting including extrusion-based and light-based processes to manufacture complex tissue constructs with biomimetic architectures. The working principles, bioinks, and supporting matrices of embedded printing processes are introduced. The effect of key processing parameters on the printing resolution, shape fidelity, and biological functions of the printed tissue constructs are discussed. Recent innovations in the processes and applications of embedded bioprinting are highlighted, such as light-based volumetric bioprinting and printing of functional vascularized organ constructs. Challenges and future perspectives with regard to translating embedded bioprinting into an effective strategy for the fabrication of functional biological constructs with biomimetic structural organizations are finally discussed. STATEMENT OF SIGNIFICANCE: It is still challenging to replicate delicate and intricate tissue-specific structural organizations using mechanically-weak hydrogels for the fabrication of functional living tissue constructs. Embedded bioprinting is an emerging 3D printing strategy that enables to produce complex tissue structures directly inside a reservoir filled with supporting matrix, which largely widens the choice of bioprinting inks to ECM-like hydrogels. Here we aim to provide a comprehensive review on various embedded bioprinting techniques mainly including extrusion-based and light-based processes. Various bioinks, supporting matrices, key processing parameters as well as their effects on the structures and biological functions of resultant living tissue constructs are discussed. We expect that it can provide an important reference and generate new insights for the bioprinting of large vascularized tissues and organs with biological functions.

Coaxial Electrohydrodynamic Bioprinting of Pre-vascularized Cell-laden Constructs for Tissue Engineering

Recapitulating the vascular networks that maintain the delivery of nutrition, oxygen, and byproducts for the living cells within the three-dimensional (3D) tissue constructs is a challenging issue in the tissue-engineering area. Here, a novel coaxial electrohydrodynamic (EHD) bioprinting strategy is presented to fabricate thick pre-vascularized cell-laden constructs. The alginate and collagen/calcium chloride solution were utilized as the outer-layer and inner-layer bioink, respectively, in the coaxial printing nozzle to produce the core-sheath hydrogel filaments. The effect of process parameters (the feeding rate of alginate and collagen and the moving speed of the printing stage) on the size of core and sheath lines within the printed filaments was investigated. The core-sheath filaments were printed in the predefined pattern to fabricate lattice hydrogel with perfusable lumen structures. Endothelialized lumen structures were fabricated by culturing the core-sheath filaments with endothelial cells laden in the core collagen hydrogel. Multilayer core-sheath filaments were successfully printed into 3D porous hydrogel constructs with a thickness of more than 3 mm. Finally, 3D pre-vascularized cardiac constructs were successfully generated, indicating the efficacy of our strategy to engineer living tissues with complex vascular structures.

3D Printing in Breast Reconstruction: From Bench to Bed

Surgical management of breast cancer often results in the absence of the breast. However, existing breast reconstruction methods may not meet the need for a replacement tissue. Tissue engineering with the use of emerging materials offers the promise of generating appropriate replacements. Three-dimensional (3D) printing technology has seen a significantly increased interest and application in medically-related fields in the recent years. This has been especially true in complex medical situations particularly when abnormal or complicated anatomical surgical considerations or precise reconstructive procedures are contemplated. In addition, 3D bio-printing which combines cells with bio-material scaffolds offers an exciting technology with significant applications in the field of tissue engineering. The purpose of this manuscript was to review a number of studies in which 3D printing technology has been used in breast reconstructive surgical procedures, and future directions and applications of 3D bio-printing.

Engineering bioinks for 3D bioprinting

In recent years, three-dimensional (3D) bioprinting has attracted wide research interest in biomedical engineering and clinical applications. This technology allows for unparalleled architecture control, adaptability and repeatability that can overcome the limits of conventional biofabrication techniques. Along with the emergence of a variety of 3D bioprinting methods, bioinks have also come a long way. From their first developments to support bioprinting requirements, they are now engineered to specific injury sites requirements to mimic native tissue characteristics and to support biofunctionality. Current strategies involve the use of bioinks loaded with cells and biomolecules of interest, without altering their functions, to deliverin situthe elements required to enhance healing/regeneration. The current research and trends in bioink development for 3D bioprinting purposes is overviewed herein.

Hydrogel-Based Bioinks for Cell Electrowriting of Well-Organized Living Structures with Micrometer-Scale Resolution

Bioprinting has become an important tool for fabricating regenerative implants and in vitro cell culture platforms. However, until today, extrusion-based bioprinting processes are limited to resolutions of hundreds of micrometers, which hamper the reproduction of intrinsic functions and morphologies of living tissues. This study describes novel hydrogel-based bioinks for cell electrowriting (CEW) of well-organized cell-laden fiber structures with diameters ranging from 5 to 40 μm. Two novel photoresponsive hydrogel bioinks, that is, based on gelatin and silk fibroin, which display distinctly different gelation chemistries, are introduced. The rapid photomediated cross-linking mechanisms, electrical conductivity, and viscosity of these two engineered bioinks allow the fabrication of 3D ordered fiber constructs with small pores (down to 100 μm) with different geometries (e.g., squares, hexagons, and curved patterns) of relevant thicknesses (up to 200 μm). Importantly, the biocompatibility of the gelatin- and silk fibroin-based bioinks enables the fabrication of cell-laden constructs, while maintaining high cell viability post printing. Taken together, CEW and the two hydrogel bioinks open up fascinating opportunities to manufacture microstructured constructs for applications in regenerative medicine and in vitro models that can better resemble cellular microenvironments.

Effects of Processing Parameters of 3D Bioprinting on the Cellular Activity of Bioinks

In this review, few established cell printing techniques along with their parameters that affect the cell viability during bioprinting are considered. 3D bioprinting is developed on the principle of additive manufacturing using biomaterial inks and bioinks. Different bioprinting methods impose few challenges on cell printing such as shear stress, mechanical impact, heat, laser radiation, etc., which eventually lead to cell death. These factors also cause alteration of cells phenotype, recoverable or irrecoverable damages to the cells. Such challenges are not addressed in detail in the literature and scientific reports. Hence, this review presents a detailed discussion of several cellular bioprinting methods and their process-related impacts on cell viability, followed by probable mitigation techniques. Most of the printable bioinks encompass cells within hydrogel as scaffold material to avoid the direct exposure of the harsh printing environment on cells. However, the advantages of printing with scaffold-free cellular aggregates over cell-laden hydrogels have emerged very recently. Henceforth, optimal and favorable crosslinking mechanisms providing structural rigidity to the cell-laden printed constructs with ideal cell differentiation and proliferation, are discussed for improved understanding of cell printing methods for the future of organ printing and transplantation.

3D printed high-resolution scaffold with hydrogel microfibers for providing excellent biocompatibility

Melt electrowriting (MEW) can print high-resolution scaffolds with the ultrafine fibers from 800 nm to 20 µm. However, the cell seeding efficiency relatively low due to the large pore size of the MEW scaffold. Here, we reported a method to solve this dilemma by electrospinning a gelatin methacrylate (GelMA) hydrogel fibers membrane (HFM) on the MEW scaffold. This composite scaffold can own the controlled structures and porosity and excellent cell seeding performance. We systematically investigate the fabrication, morphology, and biocompatibility of composite scaffolds. The implanting of human umbilical vein endothelial cells(HUVES) showed excellent adhesion and biocompatibility on the composite scaffold. Moreover, the cells migrated gradually into the MEW scaffold along the GelMA HFM to form the cell sheet. We hold the opinion that the composite scaffolds have potential applications in the field of tissue engineering repair.

High-resolution electrohydrodynamic bioprinting: a new biofabrication strategy for biomimetic micro/nanoscale architectures and living tissue constructs

Electrohydrodynamic (EHD) printing is a newly emerging additive manufacturing strategy for the controlled fabrication of three-dimensional (3D) micro/nanoscale architectures. This unique superiority makes it particularly suitable for the biofabrication of artificial tissue analogs with biomimetic structural organizations similar to the scales of native extracellular matrix (ECM) or living cells, which shows great potentials to precisely regulate cellular behaviors and tissue regeneration. Here the state-of-the-art advancements of high-resolution EHD bioprinting were reviewed mainly including melt-based and solution-based processes for the fabrication of micro/nanoscale fibrous scaffolds and living tissues constructs. The related printing materials, innovations on structure design and printing processes, functionalization of the resultant architectures as well as their effects on the mechanical and biological properties of the EHD-printed structures were introduced and analyzed. The recent explorations on the EHD cell printing for high-resolution cell-laden microgel patterning and 3D construct fabrication were highlighted. The major challenges as well as possible solutions to translate EHD bioprinting into a mature and prevalent biofabrication strategy were finally discussed.

Advances in Hybrid Fabrication toward Hierarchical Tissue Constructs

The diversity of manufacturing processes used to fabricate 3D implants, scaffolds, and tissue constructs is continuously increasing. This growing number of different applicable fabrication technologies include electrospinning, melt electrowriting, volumetric-, extrusion-, and laser-based bioprinting, the Kenzan method, and magnetic and acoustic levitational bioassembly, to name a few. Each of these fabrication technologies feature specific advantages and limitations, so that a combination of different approaches opens new and otherwise unreachable opportunities for the fabrication of hierarchical cell-material constructs. Ongoing challenges such as vascularization, limited volume, and repeatability of tissue constructs at the resolution required to mimic natural tissue is most likely greater than what one manufacturing technology can overcome. Therefore, the combination of at least two different manufacturing technologies is seen as a clear and necessary emerging trend, especially within biofabrication. This hybrid approach allows more complex mechanics and discrete biomimetic structures to address mechanotransduction and chemotactic/haptotactic cues. Pioneering milestone papers in hybrid fabrication for biomedical purposes are presented and recent trends toward future manufacturing platforms are analyzed.

Multitechnology Biofabrication: A New Approach for the Manufacturing of Functional Tissue Structures?

Most available 3D biofabrication technologies rely on single-component deposition methods, such as inkjet, extrusion, or light-assisted printing. It is unlikely that any of these technologies used individually would be able to replicate the complexity and functionality of living tissues. Recently, new biofabrication approaches have emerged that integrate multiple manufacturing technologies into a single biofabrication platform. This has led to fabricated structures with improved functionality. In this review, we provide a comprehensive overview of recent advances in the integration of different manufacturing technologies with the aim to fabricate more functional tissue structures. We provide our vision on the future of additive manufacturing (AM) technology, digital design, and the use of artificial intelligence (AI) in the field of biofabrication.

Instrument for fine control of drop-on-demand electrohydrodynamic jet printing by current measurement

In this work, an instrument of drop-on-demand electrohydrodynamic jet (DoD E-Jet) printing device equipped with a current measurement and control system was designed and developed for finely controlling the printing process. The relationships between the current and printing parameters of voltage, frequency, and flow rate were deeply investigated, and the examination data and conclusion were obtained under the condition of the needle size remaining unchanged. Especially, the equation relationship between the flow rate and current was established, which can be used for the modification of the DoD E-Jet printing process. The map describing the stable printing range, droplet size, and current was also recognized, which can help us to select parameters for stable printing. Based on the current measurement and control system and the established relationship, the optimized current and printing parameters were chosen to print uniform graphene microstructures. This instrument provides an effective method for monitoring, adjusting, and controlling the DoD E-Jet printing process and further improving the quality of the printed structures for micro/nanoelectromechanical system (M/NEMS) devices.

Fabrication of Designable and Suspended Microfibers via Low-Voltage 3D Micropatterning

Building two-dimensional (2D) and three-dimensional (3D) fibrous structures in the micro- and nanoscale will offer exciting prospects for numerous applications spanning from sensors to energy storage and tissue engineering scaffolds. Electrospinning is a well-suited technique for drawing micro- to nanoscale fibers, but current methods of building electrospun fibers in 3D are restrictive in terms of printed height, design of macroscopic fiber networks, and choice of polymer. Here, we combine low-voltage electrospinning and additive manufacturing as a method to pattern layers of suspended mesofibers. Layers of fibers are suspended between 3D-printed supports in situ in multiple fiber layers and designable orientations. We examine the key working parameters to attain a threshold for fiber suspension, use those behavioral observations to establish a "fiber suspension indicator", and demonstrate its utility through design of intricate suspended fiber architectures. Individual fibers produced by this method approach the micrometer/submicrometer scale, while the overall suspended 3D fiber architecture can span over a centimeter in height. We demonstrate an application of suspended fiber architectures in 3D cell culture, utilizing patterned fiber topography to guide the assembly of suspended high-cellular-density structures. The solution-based fiber suspension patterning process we report offers a unique competence in patterning soft polymers, including extracellular matrix-like materials, in a high resolution and aspect ratio. The platform could thus offer new design and manufacturing capabilities of devices and functional products by incorporating functional fibrous elements.

A Novel, Well-Resolved Direct Laser Bioprinting System for Rapid Cell Encapsulation and Microwell Fabrication

A direct laser bioprinting (DLBP) system is introduced in this work. The DLBP system applies visible-laser-induced photo-crosslinking at a wavelength of 405 nm using the photoinitiator VA-086. It is shown that such a system can fabricate vertical structures with fine features (less than 50 µm) and high cell viability (greater than 95%). Experimental characterizations and theoretical simulations are presented, and good agreement is seen between the experiments and theory. The DLBP system is applied to the fabrication of (1) cell-laden hydrogel microgrids, (2) hydrogel microwells, as well as a test of (3) cell encapsulation, and (4) cell seeding. The DLBP system is found to be a promising tool for bioprinting.

Advanced Material Strategies for Next-Generation Additive Manufacturing

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing.