High-Resolution 3D Printing of Stretchable Hydrogel Structures Using Optical Projection Lithography

Droplet bioprinting of acellular and cell-laden structures at high-resolutions

Advances in digital light projection(DLP) based (bio) printers have made printing of intricate structures at high resolution possible using a wide range of photosensitive bioinks. A typical setup of a DLP bioprinter includes a vat or reservoir filled with liquid bioink, which presents challenges in terms of cost associated with bioink synthesis, high waste, and gravity-induced cell settling, contaminations, or variation in bioink viscosity during the printing process. Here, we report a vat-free, low-volume, waste-free droplet bioprinting method capable of rapidly printing 3D soft structures at high resolution using model bioinks and model cells. A multiphase many-body dissipative particle dynamics model was developed to simulate the dynamic process of droplet-based DLP printing and elucidate the roles of surface wettability and bioink viscosity. Process variables such as light intensity, photo-initiator concentration, and bioink formulations were optimized to print 3D soft structures (∼0.4-3 kPa) with a typical layer thickness of 50µm, an XY resolution of 38 ± 1.5μm and Z resolution of 237 ± 5.4µm. To demonstrate its versatility, droplet bioprinting was used to print a range of acellular 3D structures such as a lattice cube, a Mayan pyramid, a heart-shaped structure, and a microfluidic chip with endothelialized channels. Droplet bioprinting, performed using model C3H/10T1/2 cells, exhibited high viability (90%) and cell spreading. Additionally, microfluidic devices with internal channel networks lined with endothelial cells showed robust monolayer formation while osteoblast-laden constructs showed mineral deposition upon osteogenic induction. Overall, droplet bioprinting could be a low-cost, no-waste, easy-to-use, method to make customized bioprinted constructs for a range of biomedical applications.

Evaluation of Various Types of Alginate Inks for Light-Mediated Extrusion 3D Printing

Naturally derived biopolymers modifying or combining with other components are excellent candidates to promote the full potential of additive manufacturing in biomedicine, cosmetics, and the food industry. This work aims to develop new photo-cross-linkable alginate-based inks for extrusion 3D printing. Specifically, this work is focused on the effect of the addition of cross-linkers with different chemical structures (polyethylene glycol diacrylate (PEGDA), N,N'-methylenebisacrylamide (NMBA), and acrylic acid (AA)) in the potential printability and physical properties of methacrylated alginate (AlgMe) hydrogels. Although all inks showed maximum photo-curing conversions and gelation times less than 2 min, only those structures printed with the inks incorporating cross-linking agents with flexible and long chain structure (PEGDA and AA) displayed acceptable size accuracy (~0.4-0.5) and printing index (Pr ~1.00). The addition of these cross-linking agents leads to higher Young's moduli (from 1.6 to 2.0-2.6 KPa) in the hydrogels, and their different chemical structures results in variations in their mechanical and rheological properties. However, similar swelling ability (~15 swelling factor), degradability (~45 days 100% weight loss), and cytocompatibility (~100%) were assessed in all the systems, which is of great importance for the final applicability of these hydrogels.

Photocuring 3D Printing of Hydrogels: Techniques, Materials, and Applications in Tissue Engineering and Flexible Devices

Photocuring 3D printing of hydrogels, with sophisticated, delicate structures and biocompatibility, attracts significant attention by researchers and possesses promising application in the fields of tissue engineering and flexible devices. After years of development, photocuring 3D printing technologies and hydrogel inks make great progress. Herein, the techniques of photocuring 3D printing of hydrogels, including direct ink writing (DIW), stereolithography (SLA), digital light processing (DLP), continuous liquid interface production (CLIP), volumetric additive manufacturing (VAM), and two photon polymerization (TPP) are reviewed. Further, the raw materials for hydrogel inks (photocurable polymers, monomers, photoinitiators, and additives) and applications in tissue engineering and flexible devices are also reviewed. At last, the current challenges and future perspectives of photocuring 3D printing of hydrogels are discussed.

Three-Dimensional Printing Strategies for Enhanced Hydrogel Applications

This study explores the dynamic field of 3D-printed hydrogels, emphasizing advancements and challenges in customization, fabrication, and functionalization for applications in biomedical engineering, soft robotics, and tissue engineering. It delves into the significance of tailored biomedical scaffolds for tissue regeneration, the enhancement in bioinks for realistic tissue replication, and the development of bioinspired actuators. Additionally, this paper addresses fabrication issues in soft robotics, aiming to mimic biological structures through high-resolution, multimaterial printing. In tissue engineering, it highlights efforts to create environments conducive to cell migration and functional tissue development. This research also extends to drug delivery systems, focusing on controlled release and biocompatibility, and examines the integration of hydrogels with electronic components for bioelectronic applications. The interdisciplinary nature of these efforts highlights a commitment to overcoming material limitations and optimizing fabrication techniques to realize the full potential of 3D-printed hydrogels in improving health and well-being.

Droplet bioprinting of acellular and cell-laden structures at high-resolutions

Advances in Digital Light Processing (DLP) based (bio) printers have made printing of intricate structures at high resolution possible using a wide range of photosensitive bioinks. A typical setup of a DLP bioprinter includes a vat or reservoir filled with liquid bioink, which presents challenges in terms of cost associated with bioink synthesis, high waste, and gravity-induced cell settling, contaminations, or variation in bioink viscosity during the printing process. Here, we report a vat-free, low-volume, waste-free droplet bioprinting method capable of rapidly printing 3D soft structures at high resolution using model bioinks. A multiphase many-body dissipative particle dynamics (mDPD) model was developed to simulate the dynamic process of droplet-based DLP printing and elucidate the roles of surface wettability and bioink viscosity. Process variables such as light intensity, photo-initiator concentration, and bioink formulations were optimized to print 3D soft structures (∼0.4 to 3 kPa) with an XY resolution of 38 ± 1.5 μm and Z resolution of 237±5.4 μm. To demonstrate its versatility, droplet bioprinting was used to print a range of acellular 3D structures such as a lattice cube, a Mayan pyramid, a heart-shaped structure, and a microfluidic chip with endothelialized channels. Droplet bioprinting, performed using model C3H/10T1/2 cells, exhibited high viability (90%) and cell spreading. Additionally, microfluidic devices with internal channel network lined with endothelial cells showed robust monolayer formation while osteoblast-laden constructs showed mineral deposition upon osteogenic induction. Overall, droplet bioprinting could be a low-cost, no-waste, easy-to-use, method to make customized bioprinted constructs for a range of biomedical applications.

Printing Double-Network Tough Hydrogels Using Temperature-Controlled Projection Stereolithography (TOPS)

We report a new method to shape double-network (DN) hydrogels into customized 3D structures that exhibit superior mechanical properties in both tension and compression. A one-pot prepolymer formulation containing photo-cross-linkable acrylamide and thermoreversible sol-gel κ-carrageenan with a suitable cross-linker and photoinitiators/absorbers is optimized. A new TOPS system is utilized to photopolymerize the primary acrylamide network into a 3D structure above the sol-gel transition of κ-carrageenan (80 °C), while cooling down generates the secondary physical κ-carrageenan network to realize tough DN hydrogel structures. 3D structures, printed with high lateral (37 μm) and vertical (180 μm) resolutions and superior 3D design freedoms (internal voids), exhibit ultimate stress and strain of 200 kPa and 2400%, respectively, under tension and simultaneously exhibit a high compression stress of 15 MPa with a strain of 95%, both with high recovery rates. The roles of swelling, necking, self-healing, cyclic loading, dehydration, and rehydration on the mechanical properties of printed structures are also investigated. To demonstrate the potential of this technology to make mechanically reconfigurable flexible devices, we print an axicon lens and show that a Bessel beam can be dynamically tuned via user-defined tensile stretching of the device. This technique can be broadly applied to other hydrogels to make novel smart multifunctional devices for a range of applications.

Complex Living Materials Made by Light-Based Printing of Genetically Programmed Bacteria

Living materials with embedded microorganisms can genetically encode attractive sensing, self-repairing, and responsive functionalities for applications in medicine, robotics, and infrastructure. While the synthetic toolbox for genetically engineering bacteria continues to expand, technologies to shape bacteria-laden living materials into complex 3D geometries are still rather limited. Here, it is shown that bacteria-laden hydrogels can be shaped into living materials with unusual architectures and functionalities using readily available light-based printing techniques. Bioluminescent and melanin-producing bacteria are used to create complex materials with autonomous chemical-sensing capabilities by harnessing the metabolic activity of wild-type and engineered microorganisms. The shaping freedom offered by printing technologies and the rich biochemical diversity available in bacteria provides ample design space for the creation and exploration of complex living materials with programmable functionalities for a broad range of applications.

Three-Dimensional Printing of Double-Network Hydrogels: Recent Progress, Challenges, and Future Outlook

Hydrogels are widely used materials due to their biocompatibility, their ability to mimic the hydrated and porous extracellular microenvironment, as well as their ability to tune both mechanical and biochemical properties. However, most hydrogels lack mechanical toughness, and shaping them into complicated three-dimensional (3D) structures remains challenging. In the past decade, tough and stretchable double-network hydrogels (DN gels) were developed for tissue engineering, soft robotics, and applications that require a combination of high-energy dissipation and large deformations. Although DN gels were processed into simple shapes by using conventional casting and molding methods, new 3D printing methods have enabled the shaping of DN gels into structurally complex 3D geometries. This review will describe the state-of-art technologies for shaping tough and stretchable DN gels into custom geometries by using conventional molding and casting, extrusion, and optics-based 3D printing, as well as the key challenges and future outlook in this field.

Simultaneous One-Pot Interpenetrating Network Formation to Expand 3D Processing Capabilities

The incorporation of a secondary network into traditional single-network hydrogels can enhance mechanical properties, such as toughness and loading to failure. These features are important for many applications, including as biomedical materials; however, the processing of interpenetrating polymer network (IPN) hydrogels is often limited by their multistep fabrication procedures. Here, a one-pot scheme for the synthesis of biopolymer IPN hydrogels mediated by the simultaneous crosslinking of two independent networks with light, namely: i) free-radical crosslinking of methacrylate-modified hyaluronic acid (HA) to form the primary network and ii) thiol-ene crosslinking of norbornene-modified HA with thiolated guest-host assemblies of adamantane and β-cyclodextrin to form the secondary network, is reported. The mechanical properties of the IPN hydrogels are tuned by changing the network composition, with high water content (≈94%) hydrogels exhibiting excellent work of fracture, tensile strength, and low hysteresis. As proof-of-concept, the IPN hydrogels are implemented as low-viscosity Digital Light Processing resins to fabricate complex structures that recover shape upon loading, as well as in microfluidic devices to form deformable microparticles. Further, the IPNs are cytocompatible with cell adhesion dependent on the inclusion of adhesive peptides. Overall, the enhanced processing of these IPN hydrogels will expand their utility across applications.

Femtosecond Laser Densification of Hydrogels to Generate Customized Volume Diffractive Gratings

Inspired by nature's ability to shape soft biological materials to exhibit a range of optical functionalities, we report femtosecond (fs) laser-induced densification as a new method to generate volume or subsurface diffractive gratings within ordinary hydrogel materials. We characterize the processing range in terms of fs laser power, speed, and penetration depths for achieving densification within poly(ethylene glycol) diacrylate (PEGDA) hydrogel and characterize the associated change in local refractive index (RI). The RI change facilitates the fabrication of custom volume gratings (parallel line, grid, square, and ring gratings) within PEGDA. To demonstrate this method's broad applicability, fs laser densification was used to generate line gratings within the phenylboronic acid (PBA) hydrogel, which is known to be responsive to changes in pH. In the future, this technique can be used to convert ordinary hydrogels into multicomponent biophotonic systems.

Review: Auxetic Polymer-Based Mechanical Metamaterials for Biomedical Applications

Over the last three decades but more particularly during the last 5 years, auxetic mechanical metamaterials constructed from precisely architected polymer-based materials have attracted considerable attention due to their fascinating mechanical properties. These materials present a negative Poisson's ratio and therefore unusual mechanical behavior, which has resulted in enhanced static modulus, energy adsorption, and shear resistance, as compared with the bulk properties of polymers. Novel advanced polymer processing and fabrication techniques, and in particular additive manufacturing, allow one to design complex and customizable polymer architectures that are particularly relevant to fabricate auxetic mechanical metamaterials. Although these metamaterials exhibit exotic mechanical properties with potential applications in several engineering fields, biomedical applications seem to be one of the most relevant with a growing number of articles published over recent years. As a result, special focus is needed to understand the potential of these structures and foster theoretical and experimental investigations on the potential benefits of the unusual mechanical properties of these materials on the way to high performance biomedical applications. The present Review provides up to date information on the recent progress of polymer-based auxetic mechanical metamaterials mainly fabricated using additive manufacturing methods with a special focus toward biomedical applications including tissue engineering as well as medical devices including stents and sensors.

Polarization-modulated grating interferometer by conical diffraction

The grating interferometer in the Littrow configuration uses quarter wave plates (QWPs) to modulate the polarization in the measurement system to determine the autocollimation optical path. Fabrication errors and mounting errors of the QWPs lead to phase changes in the grating interferometer that generate measurement errors. As an alternative, we propose a grating interferometer that produces conical diffraction. Using the grating instead of QWPs to modulate the beam's polarization bypasses this source of error. A 45 mm range experiment was performed that yielded a repeated measurement error of 40 nm. Experiments show that the system has a simple structure and good repeatability and is capable of high-precision displacement measurements.

Crosslinking Trends in Multicomponent Hydrogels for Biomedical Applications

Multicomponent-based hydrogels are well established candidates for biomedical applications. However, certain aspects of multicomponent systems, e.g., crosslinking, structural binding, network formation, proteins/drug incorporation, etc., are challenging aspects to modern biomedical research. The types of crosslinking and network formation are crucial for the effective combination of multiple component systems. The creation of a complex system in the overall structure and the crosslinking efficiency of different polymeric chains in an organized fashion are crucially important, especially when the materials are for biomedical applications. Therefore, the engineering of hydrogel has to be, succinctly understood, carefully formulated, and expertly designed. The different crosslinking methods in use, hydrogen bonding, electrostatic interaction, coordination bonding, and self-assembly. The formations of double, triple, and multiple networks, are well established. A systematic study of the crosslinking mechanisms in multicomponent systems, in terms of the crosslinking types, network formation, intramolecular bonds between different structural units, and their potentials for biomedical applications, is lacking and therefore, these aspects require investigations. To this end, the present review, focuses on the recent advances in areas of the physical, chemical, and enzymatic crosslinking methods that are often, employed for the designing of multicomponent hydrogels.

Enhancing Biopolymer Hydrogel Functionality through Interpenetrating Networks

Traditional hydrogels are strong candidates for biomedical applications; however, they may suffer from drawbacks such as weak mechanics, static properties, and an inability to fully replicate aspects of the cellular microenvironment. These challenges can be addressed through the incorporation of second networks to form interpenetrating polymer network (IPN) hydrogels. The objective of this review is to establish clear trends on the enhanced functionality achieved by incorporating secondary networks into traditional, biopolymer-based hydrogels. These include mechanical reinforcement, 'smart' systems that respond to external stimuli, and the ability to tune cell-material interactions. Through attention to network structure and chemistry, IPN hydrogels may advance to meet challenging criteria for a wide range of biomedical fields.

Hydrogel-based diffractive optical elements (hDOEs) using rapid digital photopatterning

Hydrogels, due to their optical transparency and biocompatibility, have emerged as an excellent alternative to conventional optical materials for biomedical applications. Advances in microfabrication techniques have helped convert conventional hydrogels into optically functional materials such as hydrogel-based diffraction optical elements (hDOEs). However, key challenges related to device customization and ease/speed of fabrication need to be addressed to enable widespread utility and acceptance of hDOEs in the field. Here, we report rapid printing of customized hDOEs on polyethylene glycol diacrylate (PEGDA) hydrogel using digital photopatterning; a novel method that combines simulated computer-generated hologram (SCGH) and projection photolithography. To showcase the versatility of this approach, a range of hDOEs are demonstrated, including 1D/2D diffraction gratings, Dammann grating, Fresnel zone plate (FZP) lens, fork-shaped grating and computer-generated hologram (CGH) of arbitrary pattern. Results demonstrate that printed hDOEs exhibit optical performance that is comparable with devices made with conventional materials. This versatile strategy can be potentially implemented with other photosensitive hydrogels to achieve user-defined hDOEs in a time-efficient and cost-effective fashion.

Everything in its right place: controlling the local composition of hydrogels using microfluidic traps

Many natural materials display locally varying compositions that impart unique mechanical properties to them which are still unmatched by manmade counterparts. Synthetic materials often possess structures that are well-defined on the molecular level, but poorly defined on the microscale. A fundamental difference that leads to this dissimilarity between natural and synthetic materials is their processing. Many natural materials are assembled from compartmentalized reagents that are released in well-defined and spatially confined regions, resulting in locally varying compositions. By contrast, synthetic materials are typically processed in bulk. Inspired by nature, we introduce a drop-based technique that enables the design of microstructured hydrogel sheets possessing tuneable locally varying compositions. This control in the spatial composition and microstructure is achieved with a microfluidic Hele-Shaw cell that possesses traps with varying trapping strengths to selectively immobilize different types of drops. This modular platform is not limited to the fabrication of hydrogels but can be employed for any material that can be processed into drops and solidified within them. It likely opens up new possibilities for the design of structured, load-bearing hydrogels, as well as for the next generation of soft actuators and sensors.

Oxygen-Permeable Films for Continuous Additive, Subtractive, and Hybrid Additive/Subtractive Manufacturing

In the past 5 years, oxygen-permeable films have been widely used for continuous additive manufacturing. These films create a polymerization inhibition zone that facilitates continuous printing in the additive mode of fabrication. Typically, oxygen-permeable films made out of Teflon are currently used. These films are expensive and are not commonly available. Hence, this research work investigates the feasibility of using commonly available low-cost oxygen-permeable films made from polydimethylsiloxane (PDMS) and polyurethane for continuous additive manufacturing. We also characterize the ablation depth range that can be achieved using these films and the potential use for subtractive ablation-based manufacturing as well as hybrid additive/subtractive manufacturing. Results demonstrate that the PDMS films (600 μm thick) can be used for both additive and subtractive modes, whereas spin-coated PDMS thin film (40 μm thick) on glass coverslip and breathe-easy polyurethane film (20 μm thick) laminated on glass coverslip are suitable only for additive mode of fabrication. The latter two films are oxygen impermeable, however, they retain oxygen, which is capable of creating dead zone and thereby facilitates continuous printing. We anticipate that this work will help researchers to choose the appropriate oxygen-permeable film for continuous additive, subtractive, and hybrid additive/subtractive manufacturing of complex three-dimensional structures for a range of applications.