Functional Polymers and Nanocomposites for 3D Printing of Smart Structures and Devices

A review on intelligence of cellulose based materials

Cellulose based materials are widely used in various fields such as papermaking, packaging, composite materials, textiles and clothing due to their diverse types, environmental friendliness, natural degradation, high specific strength, and low cost. The intelligence of cellulose based materials will further expand their application fields. This article first gives an in-depth analyzation on the intelligent structural design of these materials according to the two major categories of isotropic and anisotropic, then lists the main preparation methods of cellulose based intelligent materials. Subsequently, this article systematically summarizes the recent intelligent response methods and characteristics of cellulose based materials, and extensively elaborates on the intelligent application of these materials. Finally, the prospects for the intelligence of cellulose based materials are discussed.

3D-Printed Polycaprolactone-Based Containing Calcium Zirconium Silicate: Bioactive Scaffold for Accelerating Bone Regeneration

There is an essential clinical need to develop rapid process scaffolds to repair bone defects. The current research presented the development of calcium zirconium silicate/polycaprolactone for bone tissue engineering utilising melt extrusion-based 3D printing. Calcium zirconium silicate (CZS) nanoparticles were added to polycaprolactone (PCL) porous scaffolds to enhance their biological and mechanical properties, while the resulting properties were studied extensively. No significant difference was found in the melting point of the samples, while the crystallisation temperature points of the samples containing bioceramic increased from 36.1 to 40.2 °C. Thermal degradation commenced around 350 °C for all materials. According to our results, increasing the CZS content from 0 to 40 wt.% (PC40) in porous scaffolds (porosity about 55-62%) improved the compressive strength from 2.8 to 10.9 MPa. Furthermore, apatite formation ability in SBF solution increased significantly by enhancing the CZS percentage. According to MTT test results, the viability of MG63 cells improved remarkably (~29%) in PC40 compared to pure PCL. These findings suggest that a 3D-printed PCL/CZS composite scaffold can be fabricated successfully and shows great potential as an implantable material for bone tissue engineering applications.

Exploring the Effectiveness of Carboxymethylated and Crosslinked Albizia Procera Gum in Diltiazem Hydrochloride Matrix Tablets: A Comparative Analysis

This study investigates the efficacy of modified Albizia procera gum as a release-retardant polymer in Diltiazem hydrochloride (DIL) matrix tablets. Carboxymethylated Albizia procera gum (CAP) and ionically crosslinked carboxymethylated Albizia procera gum (Ca-CAP) were utilized, with Ca-CAP synthesized via crosslinking CAP with calcium ions (Ca2+) using calcium chloride (CaCl2). FTIR analysis affirmed polymer compatibility, while Differential scanning calorimetry (DSC) and X-ray diffraction (XRD) assessed thermal behavior and crystallinity, respectively. Zeta potential analysis explored surface charge and electrostatic interactions, while rheology examined flow and viscoelastic properties. Swelling and erosion kinetics provided insights into water penetration and stability. CAP's carboxymethyl groups (-CH2-COO-) heightened divalent cation reactivity, and crosslinking with CaCl2 produced Ca-CAP through -CH2-COO- and Ca2+ interactions. Structural similarities between the polymers were revealed by FTIR, with slight differences. DSC indicated modified thermal behavior in Ca-CAP, while Zeta potential analysis showcased negative charges, with Ca-CAP exhibiting lower negativity. XRD highlighted increased crystallinity in Ca-CAP due to calcium crosslinking. Minimal impact on RBC properties was observed with both polymers compared to the positive control as water for injection (WFI). Ca-CAP exhibited improved viscosity, strength, controlled swelling, and erosion, allowing prolonged drug release compared to CAP. Stability studies confirmed consistent six-month drug release, emphasizing Ca-CAP's potential as a stable, sustained drug delivery system over CAP. Robustness and accelerated stability tests supported these findings, underscoring the promise of Ca-CAP in controlled drug release applications.

3D Printing of Self-Healing Materials

This review article presents a comprehensive overview of the latest advances in the field of 3D printable structures with self-healing properties. Three-dimensional printing (3DP) is a versatile technology that enables the rapid manufacturing of complex geometric structures with precision and functionality not previously attainable. However, the application of 3DP technology is still limited by the availability of materials with customizable properties specifically designed for additive manufacturing. The addition of self-healing properties within 3D printed objects is of high interest as it can improve the performance and lifespan of structural components, and even enable the mimicking of living tissues for biomedical applications, such as organs printing. The review will discuss and analyze the most relevant results reported in recent years in the development of self-healing polymeric materials that can be processed via 3D printing. After introducing the chemical and physical self-healing mechanism that can be exploited, the literature review here reported will focus in particular on printability and repairing performances. At last, actual perspective and possible development field will be critically discussed.

Recent advances in 3D bioprinted cartilage-mimicking constructs for applications in tissue engineering

Human cartilage tissue can be categorized into three types: hyaline cartilage, elastic cartilage and fibrocartilage. Each type of cartilage tissue possesses unique properties and functions, which presents a significant challenge for the regeneration and repair of damaged tissue. Bionics is a discipline in which humans study and imitate nature. A bionic strategy based on comprehensive knowledge of the anatomy and histology of human cartilage is expected to contribute to fundamental study of core elements of tissue repair. Moreover, as a novel tissue-engineered technology, 3D bioprinting has the distinctive advantage of the rapid and precise construction of targeted models. Thus, by selecting suitable materials, cells and cytokines, and by leveraging advanced printing technology and bionic concepts, it becomes possible to simultaneously realize multiple beneficial properties and achieve improved tissue repair. This article provides an overview of key elements involved in the combination of 3D bioprinting and bionic strategies, with a particular focus on recent advances in mimicking different types of cartilage tissue.

Deep Learning in Mechanical Metamaterials: From Prediction and Generation to Inverse Design

Mechanical metamaterials are meticulously designed structures with exceptional mechanical properties determined by their microstructures and constituent materials. Tailoring their material and geometric distribution unlocks the potential to achieve unprecedented bulk properties and functions. However, current mechanical metamaterial design considerably relies on experienced designers' inspiration through trial and error, while investigating their mechanical properties and responses entails time-consuming mechanical testing or computationally expensive simulations. Nevertheless, recent advancements in deep learning have revolutionized the design process of mechanical metamaterials, enabling property prediction and geometry generation without prior knowledge. Furthermore, deep generative models can transform conventional forward design into inverse design. Many recent studies on the implementation of deep learning in mechanical metamaterials are highly specialized, and their pros and cons may not be immediately evident. This critical review provides a comprehensive overview of the capabilities of deep learning in property prediction, geometry generation, and inverse design of mechanical metamaterials. Additionally, this review highlights the potential of leveraging deep learning to create universally applicable datasets, intelligently designed metamaterials, and material intelligence. This article is expected to be valuable not only to researchers working on mechanical metamaterials but also those in the field of materials informatics.

Self-Healing Polymeric Materials and Composites for Additive Manufacturing

Self-healing polymers have received widespread attention due to their ability to repair damage autonomously and increase material stability, reliability, and economy. However, the processability of self-healing materials has yet to be studied, limiting the application of rich self-healing mechanisms. Additive manufacturing effectively improves the shortcomings of conventional processing while increasing production speed, accuracy, and complexity, offering great promise for self-healing polymer applications. This article summarizes the current self-healing mechanisms of self-healing polymers and their corresponding additive manufacturing methods, and provides an outlook on future developments in the field.

Translational biomaterials of four-dimensional bioprinting for tissue regeneration

Bioprinting is an additive manufacturing technique that combines living cells, biomaterials, and biological molecules to develop biologically functional constructs. Three-dimensional (3D) bioprinting is commonly used as anin vitromodeling system and is a more accurate representation ofin vivoconditions in comparison to two-dimensional cell culture. Although 3D bioprinting has been utilized in various tissue engineering and clinical applications, it only takes into consideration the initial state of the printed scaffold or object. Four-dimensional (4D) bioprinting has emerged in recent years to incorporate the additional dimension of time within the printed 3D scaffolds. During the 4D bioprinting process, an external stimulus is exposed to the printed construct, which ultimately changes its shape or functionality. By studying how the structures and the embedded cells respond to various stimuli, researchers can gain a deeper understanding of the functionality of native tissues. This review paper will focus on the biomaterial breakthroughs in the newly advancing field of 4D bioprinting and their applications in tissue engineering and regeneration. In addition, the use of smart biomaterials and 4D printing mechanisms for tissue engineering applications is discussed to demonstrate potential insights for novel 4D bioprinting applications. To address the current challenges with this technology, we will conclude with future perspectives involving the incorporation of biological scaffolds and self-assembling nanomaterials in bioprinted tissue constructs.

Biomaterials-based additive manufacturing for customized bioengineering in management of otolaryngology: a comprehensive review

Three-dimensional (3D)/four-dimensional (4D) printing, also known as additive manufacturing or fast prototyping, is a manufacturing technique that uses a digital model to generate a 3D/4D solid product. The usage of biomaterials with 3D/4D printers in the pharma and healthcare industries is gaining significant popularity. 3D printing has mostly been employed in the domain of otolaryngology to build portable anatomical models, personalized patient-centric implants, biologic tissue scaffolds, surgical planning in individuals with challenging conditions, and surgical training. Although identical to 3D printing technology in this application, 4D printing technology comprises a fourth dimension of time. With the use of 4D printing, a printed structure may alter over time under various stimuli. Smart polymeric materials are also generally denoted as bioinks are frequently employed in tissue engineering applications of 3D/4D printing. In general, 4D printing could significantly improve the safety and efficacy of otolaryngology therapies. The use of bioprinting in otolaryngology has an opportunity to transform the treatment of diseases influencing the ear, nose, and throat as well as the field of tissue regeneration. The present review briefs on polymeric material including biomaterials and cells used in the manufacturing of patient centric 3D/4D bio-printed products utilized in management of otolaryngology.

Embedded Direct Ink Writing 3D Printing of UV Curable Resin/Sepiolite Composites with Nano Orientation

Among the various 3D printing methods, direct ink writing (DIW) through extrusion directly affects the microstructure and properties of materials. However, use of nanoparticles at high concentrations is restricted due to difficulties in sufficient dispersion and the deteriorated physical properties of nanocomposites. Thus, although there are many studies on filler alignment with high-viscosity materials with a weight fraction higher than 20 wt %, not much research has been done with low-viscosity nanocomposites with less than 5 phr. Interestingly, the alignment of anisotropic particles improves the physical properties of the nanocomposite at a low concentration of nanoparticles with DIW. The rheological behavior of ink is affected by the alignment of anisotropic sepiolite (SEP) at a low concentration using the embedded 3D printing method, and silicone oil complexed with fumed silica is used as a printing matrix. A significant increase in mechanical properties is expected compared to conventional digital light processing. We clarify the synergistic effect of the SEP alignment in a photocurable nanocomposite material through physical property investigations.

Digital light processing 3D printing of dynamic magneto-responsive thiol-acrylate composites

Additive manufacturing is one of the most promising processing techniques for fabricating customized 3D objects. For the 3D printing of functional and stimuli-triggered devices, interest is steadily growing in processing materials with magnetic properties. Synthesis routes for magneto-responsive soft materials typically involve the dispersion of (nano)particles into a non-magnetic polymer matrix. Above their glass transition temperature, the shape of such composites can be conveniently adjusted by applying an external magnetic field. With their rapid response time, facile controllability, and reversible actuation, magnetically responsive soft materials can be used in the biomedical field (e.g. drug delivery, minimally invasive surgery), soft robotics or in electronic applications. Herein, we combine the magnetic response with thermo-activated healability by introducing magnetic Fe₃O₄ nanoparticles into a dynamic photopolymer network, which undergoes thermo-activated bond exchange reactions. The resin is based on a radically curable thiol-acrylate system, whose composition is optimized towards processability via digital light processing 3D printing. A mono-functional methacrylate phosphate is applied as a stabilizer to increase the resins' shelf life by preventing thiol-Michael reactions. Once photocured, the organic phosphate further acts as a transesterification catalyst and activates bond exchange reactions at elevated temperature, which render the magneto-active composites mendable and malleable. The healing performance is demonstrated by recovering magnetic and mechanical properties after the thermally triggered mending of 3D-printed structures. We further demonstrate the magnetically driven movement of 3D-printed samples, which gives rise to the potential use of these materials in healable soft devices activated by external magnetic fields.

Liquid crystal doped photopolymer micro-droplets printed by a simple and clean laser-induced forward transfer process

We print a tunable photopolymer (photopolymer dispersed liquid crystal -PDLC), using the laser-induced direct transfer technique without absorber layer, which was a challenge for this technique given the low absorption and high viscosity of PDLC, and which had not been achieved so far to our knowledge. This makes the LIFT printing process faster and cleaner and achieves a high-quality printed droplet (aspheric profile and low roughness). A femtosecond laser was needed to reach sufficiently peak energies to induce nonlinear absorption and eject the polymer onto a substrate. Only a narrow energy window allows the material to be ejected without spattering.

The load-bearing mechanism of plant wings: A multiscale structural and mechanical analysis of the T. tipu samara

Spinning winged fruits ("helicopter" samaras) generate significant lift forces at relatively low velocities, which enable the wind to disperse them across long distances. The biological material of the samara sustains the aerodynamic loadings and maintains the physical shape of the samara in the air via a yet unknown load-bearing mechanism. Here, positing that this mechanism fundamentally originates from the macro-to-microscale structural and mechanical characteristics of the samara, we use sub-micron computer tomography, electron microscopy, and multi-scale mechanical experiments to map the structural and mechanical characteristics of the tipu tree (Tipuana tipu) samara down to the micrometer length scale. Then, using theoretical models, we characterize the multiscale structural-mechanical principles of the samara and use these principles to disclose the underlying load-bearing mechanism. We found that the structural motifs of the tipu tree samara are closely analogous to various other types and forms of winged fruits, suggesting that this load-bearing mechanism is widespread in plant wings. The structural-mechanical principles governing the samara bear unconventional design concepts, which pave the way toward the development and engineering of small-scale wing elements for miniature aviation platforms with specialized mechanical capabilities. STATEMENT OF SIGNIFICANCE: The biomaterial of plant wings grants them mechanical resistance to flight forces during wind dispersal. "Helicopter seeds" demonstrate an intricate load-bearing mechanism that spans three structure-functional scales of their biomaterial. This mechanism appears widespread in plant wings and may promote novel micro-engineering design guidelines for futuristic flight materials and small-scale aviation platforms.

3D Printing of Hybrid-Hydrogel Materials for Tissue Engineering: a Critical Review

Purpose

Key natural polymers, known as hydrogels, are an important group of materials in design of tissue-engineered constructs that can provide suitable habitat for cell attachment and proliferation. However, in comparison to tissues within the body, these hydrogels display poor mechanical properties. Such properties cause challenges in 3D printing of hydrogel scaffolds as well as their surgical handling after fabrication. For this reason, the purpose of this study is to critically review the 3D printing processes of hydrogels and their characteristics for tissue engineering application.

Methods

A search of Google Scholar and PubMed has been performed from 2003 to February 2022 using a combination of keywords. A review of the types of 3D printing is presented. Additionally, different types of hydrogels and nano-biocomposite materials for 3D printing application are critically reviewed. The rheological properties and crosslinking mechanisms for the hydrogels are assessed.

Results

Extrusion-based 3D printing is the most common practice for constructing hydrogel-based scaffolds, and it allows for the use of varying types of polymers to enhance the properties and printability of the hydrogel-based scaffolds. Rheology has been found to be exceedingly important in the 3D printing process; however, shear-thinning and thixotropic characteristics should also be present in the hydrogel. Despite these features of extrusion-based 3D printing, there are limitations to its printing resolution and scale.

Conclusion

Combining natural and synthetic polymers and a variety of nanomaterials, such as metal, metal oxide, non-metal, and polymeric, can enhance the properties of hydrogel and provide additional functionality to their 3D-printed constructs.

Digital manufacturing of personalised footwear with embedded sensors

The strong clinical demand for more accurate and personalized health monitoring technologies has called for the development of additively manufactured wearable devices. While the materials palette for additive manufacturing continues to expand, the integration of materials, designs and digital fabrication methods in a unified workflow remains challenging. In this work, a 3D printing platform is proposed for the integrated fabrication of silicone-based soft wearables with embedded piezoresistive sensors. Silicone-based inks containing cellulose nanocrystals and/or carbon black fillers were thoroughly designed and used for the direct ink writing of a shoe insole demonstrator with encapsulated sensors capable of measuring both normal and shear forces. By fine-tuning the material properties to the expected plantar pressures, the patient-customized shoe insole was fully 3D printed at room temperature to measure in-situ gait forces during physical activity. Moreover, the digitized approach allows for rapid adaptation of the sensor layout to meet specific user needs and thereby fabricate improved insoles in multiple quick iterations. The developed materials and workflow enable a new generation of fully 3D printed soft electronic devices for health monitoring.

Block Copolymers in 3D/4D Printing: Advances and Applications as Biomaterials

3D printing is a manufacturing technique in constant evolution. Day by day, new materials and methods are discovered, making 3D printing continually develop. 3D printers are also evolving, giving us objects with better resolution, faster, and in mass production. One of the areas in 3D printing that has excellent potential is 4D printing. It is a technique involving materials that can react to an environmental stimulus (pH, heat, magnetism, humidity, electricity, and light), causing an alteration in their physical or chemical state and performing another function. Lately, 3D/4D printing has been increasingly used for fabricating materials aiming at drug delivery, scaffolds, bioinks, tissue engineering (soft and hard), synthetic organs, and even printed cells. The majority of the materials used in 3D printing are polymeric. These materials can be of natural origin or synthetic ones of different architectures and combinations. The use of block copolymers can combine the exemplary properties of both blocks to have better mechanics, processability, biocompatibility, and possible stimulus behavior via tunable structures. This review has gathered fundamental aspects of 3D/4D printing for biomaterials, and it shows the advances and applications of block copolymers in the field of biomaterials over the last years.

Emerging 3D bioprinting applications in plastic surgery

Plastic surgery is a discipline that uses surgical methods or tissue transplantation to repair, reconstruct and beautify the defects and deformities of human tissues and organs. Three-dimensional (3D) bioprinting has gained widespread attention because it enables fine customization of the implants in the patient's surgical area preoperatively while avoiding some of the adverse reactions and complications of traditional surgical approaches. In this paper, we review the recent research advances in the application of 3D bioprinting in plastic surgery. We first introduce the printing process and basic principles of 3D bioprinting technology, revealing the advantages and disadvantages of different bioprinting technologies. Then, we describe the currently available bioprinting materials, and dissect the rationale for special dynamic 3D bioprinting (4D bioprinting) that is achieved by varying the combination strategy of bioprinting materials. Later, we focus on the viable clinical applications and effects of 3D bioprinting in plastic surgery. Finally, we summarize and discuss the challenges and prospects for the application of 3D bioprinting in plastic surgery. We believe that this review can contribute to further development of 3D bioprinting in plastic surgery and provide lessons for related research.

The clinical significance of 4D printing

4D printing is the next step on from 3D printing involving the fourth dimension of 'time'. The programmed 4D-printed objects are capable of changing their shape in response to external stimuli, such as light, heat, or water, differentiating them from 3D-printed static objects. This technique promises new possibilities for cancer treatment, drug delivery, stent development, and tissue engineering. In this review, we focus on the development of 4D-printed objects, their clinical use, and the possibility of 5D printing, which could revolutionize the fields of biomedical engineering and drug delivery.

Three-Dimensional Printed Polyamide 12 (PA12) and Polylactic Acid (PLA) Alumina (Al2O3) Nanocomposites with Significantly Enhanced Tensile, Flexural, and Impact Properties

The effect of aluminum oxide (Al2O3) nanoparticles (NPs) as a reinforcing agent of Polyamide 12 (PA12) and Polylactic acid (PLA) in fused filament fabrication (FFF) three-dimensional printing (3DP) is reported herein for the first time. Alumina NPs are incorporated via a melt-mixing compounding process, at four different filler loadings. Neat as well as nanocomposite 3DP filaments are prepared as feedstock for the 3DP manufacturing of specimens which are thoroughly investigated for their mechanical properties. Thermogravimetric analyses (TGA) and Raman spectroscopy (RS) proved the nature of the materials. Their morphological characteristics were thoroughly investigated with scanning electron and atomic force microscopy. Al2O3 NPs exhibited a positive reinforcement mechanism at all filler loadings, while the mechanical percolation threshold with the maximum increase of performance was found between 1.0-2.0 wt.% filler loading (1.0 wt.% for PA12, 41.1%, and 56.4% increase in strength and modulus, respectively; 2.0 wt.% for PLA, 40.2%, and 27.1% increase in strength and modulus, respectively). The combination of 3DP and polymer engineering using nanocomposite PA12 and PLA filaments with low-cost filler additives, e.g., Al2O3 NPs, could open new avenues towards a series of potential applications using thermoplastic engineering polymers in FFF 3DP manufacturing.

Spray-Dried Photonic Balls with a Disordered/Ordered Hybrid Structure for Shear-Stress Indication

Optical microscale shear-stress indicator particles are of interest for the in situ recording of localized forces, e.g., during 3D printing or smart skins in robotic applications. Recently developed particle systems are based on optical responses enabled by integrated organic dyes. They thus suffer from potential chemical instability and cross-sensitivities toward humidity or temperature. These drawbacks can be circumvented using photonic balls as shear-stress indicator particles, which employ structural color as the element to record forces. Here, such photonic balls are prepared from silica and iron oxide nanoparticles via the scalable and fast spray-drying technique. Process parameters to create photonic balls with a disordered core and an ordered particle structure toward the exterior of the supraparticles are reported. This hybrid disordered-ordered structure is responsible for a color loss of the indicator particles during shear-stress application because of irreversible structural destruction. By adjusting the primary silica particle sizes, nearly all colors of the visible spectrum can be achieved and the sensitivity of the response to shear stress can be adjusted.

Modulation of bioactive calcium phosphate micro/nanoparticle size and shape during in situ synthesis of photo-crosslinkable gelatin methacryloyl based nanocomposite hydrogels for 3D bioprinting and tissue engineering

Background

The gelatin-methacryloyl (GelMA) polymer suffers shape fidelity and structural stability issues during 3D bioprinting for bone tissue engineering while homogeneous mixing of reinforcing nanoparticles is always under debate.

Method

In this study, amorphous calcium phosphates micro/nanoparticles (CNP) incorporated GelMA is synthesized by developing specific sites for gelatin structure-based nucleation and stabilization in a one-pot processing. The process ensures homogenous distribution of CNPs while different concentrations of gelatin control their growth and morphologies. After micro/nanoparticles synthesis in the gelatin matrix, methacrylation is carried out to prepare homogeneously distributed CNP-reinforced gelatin methacryloyl (CNP GelMA) polymer. After synthesis of CNP and CNP GelMA gel, the properties of photo-crosslinked 3D bioprinting scaffolds were compared with those of the conventionally fabricated ones.

Results

The shape (spindle to spherical) and size (1.753 μm to 296 nm) of the micro/nanoparticles in the GelMA matrix are modulated by adjusting the gelatin concentrations during the synthesis. UV cross-linked CNP GelMA (using Irgacure 2955) has significantly improved mechanical (three times compressive strength), 3D printability (160 layers, 2 cm self-standing 3D printed height) and biological properties (cell supportiveness with osteogenic differentiation). The photo-crosslinking becomes faster due to better methacrylation, facilitating continuous 3D bioprinting or printing.

Conclusion

For 3D bioprinting using GelMA like photo cross-linkable polymers, where structural stability and homogeneous control of nanoparticles are major concerns, CNP GelMA is beneficial for even bone tissue regeneration within short period.

Graphical Abstract

Supplementary Information

The online version contains supplementary material available at 10.1186/s40824-022-00301-6.

Polymers in Technologies of Additive and Inkjet Printing of Dosage Formulations

Technologies for obtaining dosage formulations (DF) for personalized therapy are currently being developed in the field of inkjet (2D) and 3D printing, which allows for the creation of DF using various methods, depending on the properties of pharmaceutical substances and the desired therapeutic effect. By combining these types of printing with smart polymers and special technological approaches, so-called 4D printed dosage formulations are obtained. This article discusses the main technological aspects and used excipients of a polymeric nature for obtaining 2D, 3D, 4D printed dosage formulations. Based on the literature data, the most widely used polymers, their properties, and application features are determined, and the technological characteristics of inkjet and additive 3D printing are shown. Conclusions are drawn about the key areas of development and the difficulties that arise in the search and implementation in the production of new materials and technologies for obtaining those dosage formulations.

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.

Mechanochromophore-linked Polymeric Materials with Visible Color Changes

Mechanical force as a type of stimuli for smart materials has obtained much attention in the past decade. Color-changing materials in response to mechanical stimuli have shown great potential in the applications such as sensors and displays. Mechanochromophore-linked polymeric materials, which are a growing sub-class of these materials, are discussed in detail in this review. Two main types of mechanochromophores which exhibit visible color change, summarized herein, involve either isomerization or radical generation mechanisms. This review focuses on their synthesis and incorporation into polymer matrices, the type of mechanical force used, factors affecting the mechanochromic properties, and their applications. This article is protected by copyright. All rights reserved.

Synthesis and Characterization of Carbon Nanotube-Doped Thermoplastic Nanocomposites for the Additive Manufacturing of Self-Sensing Piezoresistive Materials

We present carbon nanotube (CNT)-reinforced polypropylene random copolymer (PPR) nanocomposites for the additive manufacturing of self-sensing piezoresistive materials via fused filament fabrication. The PPR/CNT feedstock filaments were synthesized through high shear-induced melt blending with controlled CNT loading up to 8 wt % to enable three-dimensional (3D) printing of nanoengineered PPR/CNT composites. The CNTs were found to enhance crystallinity (up to 6%) in PPR-printed parts, contributing to the overall CNT-reinforcement effect that increases both stiffness and strength (increases of 56% in modulus and 40% in strength at 8 wt % CNT loading). Due to electrical conductivity (∼10^-4-10^-1 S/cm with CNT loading) imparted to the PPR by the CNT network, multifunctional in situ strain and damage sensing in 3D-printed CNT/PPR bulk composites and lattice structures are revealed. A useful range of gauge factors (k) is identified for strain sensing (k_s = 10.1-17.4) and damage sensing (k_d = 20-410) across the range of CNT loadings for the 0° print direction. Novel auxetic re-entrant and S-unit cell lattices are printed, with multifunctionality demonstrated as strain- and damage-sensing in tension. The PPR/CNT multifunctional nanocomposite lattices demonstrated here exhibit tunable strain and damage sensitivity and have application in biomedical engineering for the creation of self-sensing patient-specific devices such as orthopedic braces, where the ability to sense strain (and stress) can provide direct information for optimization of brace design/fit over the course of treatment.

Continuous Fiber-Reinforced Aramid/PETG 3D-Printed Composites with High Fiber Loading through Fused Filament Fabrication

Recent development in the field of additive manufacturing, also known as three-dimensional (3D) printing, has allowed for the incorporation of continuous fiber reinforcement into 3D-printed polymer parts. These fiber reinforcements allow for the improvement of the mechanical properties, but compared to traditionally produced composite materials, the fiber volume fraction often remains low. This study aims to evaluate the in-nozzle impregnation of continuous aramid fiber reinforcement with glycol-modified polyethylene terephthalate (PETG) using a modified, low-cost, tabletop 3D printer. We analyze how dimensional printing parameters such as layer height and line width affect the fiber volume fraction and fiber dispersion in printed composites. By varying these parameters, unidirectional specimens are printed that have an inner structure going from an array-like to a continuous layered-like structure with fiber loading between 20 and 45 vol%. The inner structure was analyzed by optical microscopy and Computed Tomography (µCT), achieving new insights into the structural composition of printed composites. The printed composites show good fiber alignment and the tensile modulus in the fiber direction increased from 2.2 GPa (non-reinforced) to 33 GPa (45 vol%), while the flexural modulus in the fiber direction increased from 1.6 GPa (non-reinforced) to 27 GPa (45 vol%). The continuous 3D reinforced specimens have quality and properties in the range of traditional composite materials produced by hand lay-up techniques, far exceeding the performance of typical bulk 3D-printed polymers. Hence, this technique has potential for the low-cost additive manufacturing of small, intricate parts with substantial mechanical performance, or parts of which only a small number is needed.

Additive manufacturing technology of polymeric materials for customized products: recent developments and future prospective

The worldwide demand for additive manufacturing (AM) is increasing due to its ability to produce more challenging customized objects based on the process parameters for engineering applications. The processing of conventional materials by AM processes is a critically demanded research stream, which has generated a path-breaking scenario in the rapid manufacturing and upcycling of plastics. The exponential growth of AM in the worldwide polymer market is expected to exceed 20 billion US dollars by 2021 in areas of automotive, medical, aerospace, energy and customized consumer products. The development of functional polymers and composites by 3D printing-based technologies has been explored significantly due to its cost-effective, easier integration into customized geometries, higher efficacy, higher precision, freedom of material utilization as compared to traditional injection molding, and thermoforming techniques. Since polymers are the most explored class of materials in AM to overcome the limitations, this review describes the latest research conducted on petroleum-based polymers and their composites using various AM techniques such as fused filament fabrication (FFF), selective laser sintering (SLS), and stereolithography (SLA) related to 3D printing in engineering applications such as biomedical, automotive, aerospace and electronics.

3D Printing-Enabled Nanoparticle Alignment: A Review of Mechanisms and Applications

3D printing (additive manufacturing (AM)) has enormous potential for rapid tooling and mass production due to its design flexibility and significant reduction of the timeline from design to manufacturing. The current state-of-the-art in 3D printing focuses on material manufacturability and engineering applications. However, there still exists the bottleneck of low printing resolution and processing rates, especially when nanomaterials need tailorable orders at different scales. An interesting phenomenon is the preferential alignment of nanoparticles that enhance material properties. Therefore, this review emphasizes the landscape of nanoparticle alignment in the context of 3D printing. Herein, a brief overview of 3D printing is provided, followed by a comprehensive summary of the 3D printing-enabled nanoparticle alignment in well-established and in-house customized 3D printing mechanisms that can lead to selective deposition and preferential orientation of nanoparticles. Subsequently, it is listed that typical applications that utilized the properties of ordered nanoparticles (e.g., structural composites, heat conductors, chemo-resistive sensors, engineered surfaces, tissue scaffolds, and actuators based on structural and functional property improvement). This review's emphasis is on the particle alignment methodology and the performance of composites incorporating aligned nanoparticles. In the end, significant limitations of current 3D printing techniques are identified together with future perspectives.

Nanosilicate-Functionalized Polycaprolactone Orchestrates Osteogenesis and Osteoblast-Induced Multicellular Interactions for Potential Endogenous Vascularized Bone Regeneration

Massive oral and maxillofacial bone defect regeneration remains a major clinical challenge due to the absence of functionalized bone grafts with ideal mechanical and proregeneration properties. In the present study, Laponite (LAP), a synthetic nanosilicate, is incorporated into polycaprolactone (PCL) to develop a biomaterial for bone regeneration. It is explored whether LAP-embedded PCL would accelerate bone regeneration by orchestrating osteoblasts to directly and indirectly induce bone regeneration processes. The results confirmed the presence of LAP in PCL, and LAP is distributed in the exfoliated structure without aggregates. Incorporation of LAP in PCL slightly improved the compressive properties. LAP-embedded PCL is biocompatible and exerts pronounced enhancements in cell viability, osteogenic differentiation, and extracellular matrix formation of osteoblasts. Furthermore, osteoblasts cultured on LAP-embedded PCL facilitate angiogenesis of vessel endothelial cells and alleviate osteoclastogenesis of osteoclasts in a paracrine manner. The addition of LAP to the PCL endows favorable bone formation in vivo. Based upon these results, LAP-embedded PCL shows great potential as an ideal bone graft that exerts both space-maintaining and vascularized bone regeneration synergistic effects and can be envisioned for oral and maxillofacial bone defect regeneration.

Comparing Performance of 3D-Printed and Injection-Molded Fiber-Reinforced Composite Parts in Ring-Spinning Traveler Application

Fiber-reinforced 3D printing (3DP) technology is a recent addition to the material extrusion-based 3DP process unlocking huge potential to apply this technology for high-performance material fabrication with complex geometries. However, in order to take the full advantage of this technology, a comparative analysis with existing technologies targeting a particular application is necessary to understand its commercial applicability. Here, an applied composite part, ring-spinning travelers, has been developed using the unique design features of fiber-reinforced 3DP technology that is beyond the capability of the currently used technology; the injection molding, quality, and performance of the printed and molded travelers were investigated and compared. The results demonstrated that fiber-reinforced 3DP is a promising technology that offers a lot of flexibility regarding reinforcement patterns and materials including both short and continuous fibers to tailor the performance, although the printed travelers showed poorer surface characteristics and wear resistance than the molded travelers. Based on the present analysis, a number of recommendations have been proposed on the design of the traveler to apply the technology effectively and use the printer to improvise and manipulate the performance of the travelers.

Polymer Chemistry for Haptics, Soft Robotics, and Human-Machine Interfaces

Progress in the field of soft devices-i.e., haptics, robotics, and human-machine interfaces (HRHMIs)-has its basis in the science of polymeric materials and chemical synthesis. However, in examining the relevant literature, we find that most developments have been enabled by off-the-shelf materials used either alone or as components of physical blends and composites. In this Progress Report, we take the position that a greater awareness of the capabilities of synthetic chemistry will accelerate the capabilities of HRHMIs. Conversely, an awareness of the applications sought by engineers working in this area may spark the development of new molecular designs and synthetic methodologies by chemists. We highlight several applications of active, stimuli-responsive polymers, which have demonstrated or shown potential use in HRHMIs. These materials share the fact that they are products of state-of-the-art synthetic techniques. The Progress Report is thus organized by the chemistry by which the materials were synthesized, including controlled radical polymerization, metal-mediated cross-coupling polymerization, ring-opening polymerization, various strategies for crosslinking, and hybrid approaches. These methods can afford polymers with multiple properties (i.e. conductivity, stimuli-responsiveness, self-healing and degradable abilities, biocompatibility, adhesiveness, and mechanical robustness) that are of great interest to scientists and engineers concerned with soft devices for human interaction.

Additive Manufacturing as a Means of Gas Sensor Development for Battery Health Monitoring

Lithium-ion batteries (LIBs) still need continuous safety monitoring based on their intrinsic properties, as well as due to the increase in their sizes and device requirements. The main causes of fires and explosions in LIBs are heat leakage and the presence of highly inflammable components. Therefore, it is necessary to improve the safety of the batteries by preventing the generation of these gases and/or their early detection with sensors. The improvement of such safety sensors requires new approaches in their manufacturing. There is a growing role for research of nanostructured sensor’s durability in the field of ionizing radiation that also can induce structural changes in the LIB’s component materials, thus contributing to the elucidation of fundamental physicochemical processes; catalytic reactions or inhibitions of the chemical reactions on which the work of the sensors is based. A current method widely used in various fields, Direct Ink Writing (DIW), has been used to manufacture heterostructures of Al2O3/CuO and CuO:Fe2O3, followed by an additional ALD and thermal annealing step. The detection properties of these 3D-DIW printed heterostructures showed responses to 1,3-dioxolan (DOL), 1,2-dimethoxyethane (DME) vapors, as well as to typically used LIB electrolytes containing LiTFSI and LiNO3 salts in a mixture of DOL:DME, as well also to LiPF6 salts in a mixture of ethylene carbonate (EC) and dimethyl carbonate (DMC) at operating temperatures of 200 °C–350 °C with relatively high responses. The combination of the possibility to detect electrolyte vapors used in LIBs and size control by the 3D-DIW printing method makes these heterostructures extremely attractive in controlling the safety of batteries.

Dynamic Nanohybrid-Polysaccharide Hydrogels for Soft Wearable Strain Sensing

Electroconductive hydrogels with stimuli-free self-healing and self-recovery (SELF) properties and high mechanical strength for wearable strain sensors is an area of intensive research activity at the moment. Most electroconductive hydrogels, however, consist of static bonds for mechanical strength and dynamic bonds for SELF performance, presenting a challenge to improve both properties into one single hydrogel. An alternative strategy to successfully incorporate both properties into one system is via the use of stiff or rigid, yet dynamic nano-materials. In this work, a nano-hybrid modifier derived from nano-chitin coated with ferric ions and tannic acid (TA/Fe@ChNFs) is blended into a starch/polyvinyl alcohol/polyacrylic acid (St/PVA/PAA) hydrogel. It is hypothesized that the TA/Fe@ChNFs nanohybrid imparts both mechanical strength and stimuli-free SELF properties to the hydrogel via dynamic catecholato-metal coordination bonds. Additionally, the catechol groups of TA provide mussel-inspired adhesion properties to the hydrogel. Due to its electroconductivity, toughness, stimuli-free SELF properties, and self-adhesiveness, a prototype soft wearable strain sensor is created using this hydrogel and subsequently tested.

Review of 3D-Printed functionalized devices for chemical and biochemical analysis

Recent developments in three-dimensional printing (3DP) have attracted the attention of analytical scientists interested in fabricating 3D devices having promising geometric functions to achieve desirable analytical performance. To break through the barrier of limited availability of 3DP materials and to extend the chemical reactivity and functionalities of devices manufactured using conventional 3DP, new approaches are being developed for the functionalization of 3D-printed devices for chemical and biochemical analysis. This Review discusses recent advances in the chemical functionalization schemes used in the main 3DP technologies, including (i) post-printing modification and surface immobilization of reactive substances on printed materials, (ii) pre-printing incorporation of reactive substances into raw printing materials, and (iii) combinations of both strategies, and their effects on the selectivity and/or sensitivity of related analytical methods. In addition, the state of the art of 3D-printed functionalized analytical devices for enzymatic derivatization and sensing, electrochemical sensing, and sample pretreatment applications are also reviewed, highlighting the importance of introducing new functional and functionalized materials to facilitate future 3DP-enabled manufacturing of multifunctional analytical devices.

Additively manufactured metastructure design for broadband radar absorption

Background

Recent advances in material science and electronics led to the rapid development of communication devices and radar detection techniques resulting in an ever-increasing demand for improved stealth performance of air vehicles during scouts. Absorber design employing metastructure concept has recently become a popular approach to improving radar stealth performance. Metastructure permits the realization of desired absorption characteristics by careful design of geometrical structures and material compositions. In this study, a metastructure designed based on graphite SLS composite for radar absorption has been demonstrated. The unit cell of the proposed structure is simulated by COMSOL Multiphysics to determine the frequency-dependent absorption characteristic of the structure. It is fabricated by using a low-cost selective laser sintering technique of additive manufacturing technology.

Results

The prototype, while measured, shows effective absorption bandwidth of 1.04 GHz that is in reasonable agreement with the simulated response of 2.08 GHz. The optimized structure exhibits ≤ − 10 dB reflectivity within a broad frequency range extending from 7.60 GHz to 18.00 GHz under normal incidence in both TE and TM polarizations. Furthermore, the absorption performance under different polarizations and incident angles has been investigated. Results indicate that the absorber displays polarization indifference and exhibits a wide-angle of incidence tolerance of up to 45° in TE polarization and 30° in TM polarizations.

Conclusion

In this paper, the feasibility of using graphite SLS material to design and 3D print a metastructure design for radar absorbing has been established as confirmed by the simulation and the measurement results. The advantages of low cost, ultra-broad operating band, wide-angle of incidence feature, and polarization insensitivity qualifies the proposed absorber for stealth and electromagnetic shielding applications.

Semi-solid extrusion 3D printing in drug delivery and biomedicine: Personalised solutions for healthcare challenges

Three-dimensional (3D) printing is an innovative additive manufacturing technology, capable of fabricating unique structures in a layer-by-layer manner. Semi-solid extrusion (SSE) is a subset of material extrusion 3D printing, and through the sequential deposition of layers of gel or paste creates objects of any desired size and shape. In comparison to other extrusion-based technologies, SSE 3D printing employs low printing temperatures which makes it suitable for drug delivery and biomedical applications, and the use of disposable syringes provides benefits in meeting critical quality requirements for pharmaceutical use. Besides pharmaceutical manufacturing, SSE 3D printing has attracted increasing attention in the field of bioelectronics, particularly in the manufacture of biosensors capable of measuring physiological parameters or as a means to trigger drug release from medical devices. This review begins by highlighting the major printing process parameters and material properties that influence the feasibility of transforming a 3D design into a 3D object, and follows with a discussion on the current SSE 3D printing developments and their applications in the fields of pharmaceutics, bioprinting and bioelectronics. Finally, the advantages and limitations of this technology are explored, before focusing on its potential clinical applications and suitability for preparing personalised medicines.

Triazine-Based Janus G-C Nucleobase as a Building Block for Self-Assembly, Peptide Nucleic Acids, and Smart Polymers

This communication reports on the utility of a triazine-based self-assembling system, reminiscent of a Janus G-C nucleobase, as a building block for developing (1) supramolecular polymers, (2) peptide nucleic acids (PNAs), and (3) smart polymers. The strategically positioned self-complementary triple H-bonding arrays DDA and AAD facilitate efficient self-assembly, leading to a linear supramolecular polymer.

A novel dual crosslinked polysaccharide hydrogel with self-healing and stretchable properties

We synthesized oxidatively modified acetoacetyl cellulose OCAA, and then a double-network polysaccharide complex hydrogel was prepared. The hydrogel exhibited very good mechanical strength, self-healing behavior, and good biocompatibility.

Digital light processing 3D printing with thiol–acrylate vitrimers

The customized fabrication of soft active devices with self-healing function is demonstrated by 3D printing with vitrimeric thiol–acrylate photopolymers.

Functional 3D printing: Approaches and bioapplications

3D printing technology has become a mature manufacturing technique, widely used for its advantages over the traditional methods, such as the end-user customization and rapid prototyping, useful in different application fields, including the biomedical one. Indeed, it represents a helpful tool for the realization of biodevices (i.e. biosensors, microfluidic bioreactors, drug delivery systems and Lab-On-Chip). In this perspective, the development of 3D printable materials with intrinsic functionalities, through the so-called 4D printing, introduces novel opportunities for the fabrication of "smart" or stimuli-responsive devices. Indeed, functional 3D printable materials can modify their surfaces, structures, properties or even shape in response to specific stimuli (such as pressure, temperature or light radiation), adding to the printed object new interesting properties exploited after the fabrication process. In this context, by combining 3D printing technology with an accurate materials' design, functional 3D objects with built-in (bio)chemical functionalities, having biorecognition, biocatalytic and drug delivery capabilities are here reported.