Aerosol Jet-Printed High-Aspect Ratio Micro-Needle Electrode Arrays Applied for Human Cerebral Organoids and 3D Neurospheroid Networks

Laser-patterned epoxy-based 3D microelectrode arrays for extracellular recording

Microelectrode arrays are commonly used to study the electrophysiological behavior of cells. Recently, there has been a growing interest in fabricating three-dimensional microelectrode arrays. Here, we present a novel process for the fast fabrication of epoxy-based 3D microelectrode array platforms with the assistance of laser-patterning technology. To this end, we photopatterned 3D pillars as scaffolds using epoxy-based dry films. Electrodes and conductor traces were fabricated by laser patterning of sputtered platinum films on top of the 3D structures, followed by deposition of parylene-C for insulation. Microelectrodes at the tip of the 3D structures were exposed using a vertical laser ablation process. The final electrodes demonstrated a low impedance of ∼10 kΩ at 1 kHz in electrochemical impedance spectroscopy measurements under physiological conditions. We investigated the maximum compression force of the 3D structures, which could withstand approximately 0.6 N per pillar. The 3D microelectrode arrays were used to record extracellular signals from HL-1 cells in culture as a proof of principle. Our results show regular firing of action potentials recorded at the tip of the 3D structures, demonstrating the possibility of recording cell signals in non-planar environments.

Engineering biomaterials by inkjet printing of hydrogels with functional particulates

Hydrogels with particulates, including proteins, drugs, nanoparticles, and cells, enable the development of new and innovative biomaterials. Precise control of the spatial distribution of these particulates is crucial to produce advanced biomaterials. Thus, there is a high demand for manufacturing methods for particle-laden hydrogels. In this context, 3D printing of hydrogels is emerging as a promising method to create numerous innovative biomaterials. Among the 3D printing methods, inkjet printing, so-called drop-on-demand (DOD) printing, stands out for its ability to construct biomaterials with superior spatial resolutions. However, its printing processes are still designed by trial and error due to a limited understanding of the ink behavior during the printing processes. This review discusses the current understanding of transport processes and hydrogel behaviors during inkjet printing for particulate-laden hydrogels. Specifically, we review the transport processes of water and particulates within hydrogel during ink formulation, jetting, and curing. Additionally, we examine current inkjet printing applications in fabricating engineered tissues, drug delivery devices, and advanced bioelectronics components. Finally, the challenges and opportunities for next-generation inkjet printing are also discussed.

Graphical Abstract

Decellularized Brain Extracellular Matrix Hydrogel Aids the Formation of Human Spinal-Cord Organoids Recapitulating the Complex Three-Dimensional Organization

The intricate electrophysiological functions and anatomical structures of spinal cord tissue render the establishment of in vitro models for spinal cord-related diseases highly challenging. Currently, both in vivo and in vitro models for spinal cord-related diseases are still underdeveloped, complicating the exploration and development of effective therapeutic drugs or strategies. Organoids cultured from human induced pluripotent stem cells (hiPSCs) hold promise as suitable in vitro models for spinal cord-related diseases. However, the cultivation of spinal cord organoids predominantly relies on Matrigel, a matrix derived from murine sarcoma tissue. Tissue-specific extracellular matrices are key drivers of complex organ development, thus underscoring the urgent need to research safer and more physiologically relevant organoid culture materials. Herein, we have prepared a rat decellularized brain extracellular matrix hydrogel (DBECMH), which supports the formation of hiPSC-derived spinal cord organoids. Compared with Matrigel, organoids cultured in DBECMH exhibited higher expression levels of markers from multiple compartments of the natural spinal cord, facilitating the development and maturation of spinal cord organoid tissues. Our study suggests that DBECMH holds potential to replace Matrigel as the standard culture medium for human spinal cord organoids, thereby advancing the development of spinal cord organoid culture protocols and their application in in vitro modeling of spinal cord-related diseases.

Optimization of process parameters in micro-scale pneumatic aerosol jet printing for high-yield precise electrodes

Aerosol jet printing (AJP) is a new non-contact direct writing technique designed to achieve precise and intricate patterns on various substrates. Specifically, the pneumatic AJP process breaks down the ink into fine particles, significantly reducing the risk of nozzle clogging and rendering it highly advantageous for industrial applications. This paper focuses on the optimization of the line electrode formation process using soluble silver clusters as the conductive ink, along with the aerosol formation procedure. The main parameters of the AJP process, namely sheath flow rate, atomizer flow rate, and dispensing speed, were identified and examined for their influence on line width and resistivity. Through this analysis, an operability window, including optimized conditions for printing high-quality lines using the AJP process, was established, along with a regression equation enabling the statistical estimation of line width. In summary, the outcomes of this investigation underscore the feasibility of an integrated printing system capable of precision control over line width, achieved through the optimization of AJP process parameters. Furthermore, it was established that pneumatic AJP offers robust process stability. The practical applicability of the proposed optimization techniques was assessed, highlighting their potential utilization in electrode formation processes within the electronic and display industry.

Three-Dimensional Morphology and Contour Quality of Conductive Lines Printed by High-Viscosity Paste Jetting

The utilization of high-viscosity paste jetting technology has the potential to significantly expand the range of available materials and enhance the three-dimensional forming efficiency compared to inkjet printing. In this study, the three-dimensional morphology and contour quality of lines printed using high-viscosity silver paste were investigated. Four types of lines were identified based on differences in the printing shape, and contour fluctuation evaluation indices were defined in both the transverse and longitudinal directions to establish quantitative distinction principles. Based on the research of inkjet printing, a modified theoretical model relating the dimensionless line width and droplet spacing was established considering the cross-sectional characteristics of the lines printed by high-viscosity paste jetting. With the establishment of mathematical models, distinction criteria between various line shapes were obtained and the printable range of uniform lines was determined. Finally, based on response surface methodology, the influences of single droplet jetting parameters, the line printing speed, and their interactions on the line contour fluctuation were analyzed. This study involved theoretical and experimental research on the line morphology and contour quality, which can provide support for control of the line printing quality in high-viscosity paste jetting technology.