i3DP, a robust 3D printing approach enabling genetic post-printing surface modification

Biomimetic Superhydrophobic Materials through 3D Printing: Progress and Challenges

Superhydrophobicity, a unique natural phenomenon observed in organisms such as lotus leaves and desert beetles, has inspired extensive research on biomimetic materials. Two main superhydrophobic effects have been identified: the "lotus leaf effect" and the "rose petal effect", both showing water contact angles larger than 150°, but with differing contact angle hysteresis values. In recent years, numerous strategies have been developed to fabricate superhydrophobic materials, among which 3D printing has garnered significant attention due to its rapid, low-cost, and precise construction of complex materials in a facile way. In this minireview, we provide a comprehensive overview of biomimetic superhydrophobic materials fabricated through 3D printing, focusing on wetting regimes, fabrication techniques, including printing of diverse micro/nanostructures, post-modification, and bulk material printing, and applications ranging from liquid manipulation and oil/water separation to drag reduction. Additionally, we discuss the challenges and future research directions in this burgeoning field.

Large-Scale, Abrasion-Resistant, and Solvent-Free Superhydrophobic Objects Fabricated by a Selective Laser Sintering 3D Printing Strategy

Manufacturing abrasion-resistant superhydrophobic matters is challenging due to the fragile feature of the introduced micro-/nanoscale surface roughness. Besides the long-term durability, large scale at meter level, and 3D complex structures are of great importance for the superhydrophobic objects used across diverse industries. Here it is shown that abrasion-resistant, half-a-meter scaled superhydrophobic objects can be one-step realized by the selective laser sintering (SLS) 3D printing technology using hydrophobic-fumed-silica (HFS)/polymer composite grains. The HFS grains serve as the hydrophobic guests while the sintered polymeric network provides the mechanical strength, leading to low-adhesion, intrinsic superhydrophobic objects with desired 3D structures. It is found that as-printed structures remained anti-wetting capabilities even after undergoing different abrasion tests, including knife cutting test, rude file grinding test, 1000 cycles of sandpaper friction test, tape test and quicksand impacting test, illustrating their abrasion-resistant superhydrophobic stability. This strategy is applied to manufacture a shell of the unmanned aerial vehicle and an abrasion-resistant superhydrophobic shoe, showing the industrial customization of large-scale superhydrophobic objects. The findings thus provide insight for designing intrinsic superhydrophobic objects via the SLS 3D printing strategy that might find use in drag-reduce, anti-fouling, or other industrial fields in harsh operating environments.

Superhydrophobic SLA 3D printed materials modified with nanoparticles biomimicking the hierarchical structure of a rice leaf

The rice leaf, combining the surface properties of lotus leaves and shark skin, presents outstanding superhydrophobic properties motivating its biomimesis. We created a novel biomimetic rice-leaf superhydrophobic surface by a three-level hierarchical structure, using for a first time stereolithographic (SLA) 3D printed channels (100µm width) with an intrinsic roughness from the printing filaments (10µm), and coated with TiO₂ nanoparticles (22 and 100nm). This structure presents a maximum advancing contact angle of 165° characterized by lower both anisotropy and hysteresis contact angles than other 3D printed surfaces, due to the presence of air pockets at the surface/water interface (Cassie-Baxter state). Dynamic water-drop tests show that the biomimetic surface presents self-cleaning, which is reduced under UV-A irradiation. The biomimetic surface further renders an increased floatability to 3D printed objects meaning a drag-reduction due to reduced water/solid contact area. Numerical simulations of a channel with a biomimetic wall confirm that the presence of air is essential to understand our results since it increases the average velocity and decreases the friction factor due to the presence of a wall-slip velocity. Our findings show that SLA 3D printing is an appropriate approach to develop biomimetic superhydrophobic surfaces for future applications in anti-fouling and drag-reduction devices.

Living Polymer Networks Prepared by Controlled Radical Polymerization Techniques

Controlled radical polymerization (CRP) techniques have become widely accepted and used in polymer research and development. While much has been done towards their traditional usage in linear and branched systems,...

Chemical and Mechanical Tunability of 3D-Printed Dynamic Covalent Networks Based on Boronate Esters

As the scope of additive manufacturing broadens, interest has developed in 3D-printed objects that are derived from recyclable resins with chemical and mechanical tunability. Dynamic covalent bonds have the potential to not only increase the sustainability of 3D-printed objects, but also serve as reactive sites for postprinting derivatization. In this study, we use boronate esters as a key building block for the development of catalyst-free, 3D-printing resins with the ability to undergo room-temperature exchange at the cross-linking sites. The orthogonality of boronate esters is exploited in fast-curing, oxygen-tolerant thiol-ene resins in which the dynamic character of 3D-printed objects can be modulated by the addition of a static, covalent cross-linker with no room-temperature bond exchange. This allows the mechanical properties of printed parts to be varied between those of a traditional thermoset and a vitrimer. Objects printed with a hybrid dynamic/static resin exhibit a balance of structural stability (residual stress = 18%) and rapid exchange (characteristic relaxation time = 7 s), allowing for interfacial welding and postprinting functionalization. Modulation of the cross-linking density postprinting is enabled by selective hydrolysis of the boronate esters to generate networks with swelling capacities tunable from 1.3 to 3.3.

Selective Fluorination of the Surface of Polymeric Materials after Stereolithography 3D Printing

With the microfluidics community embracing 3D resin printing as a rapid fabrication method, controlling surface chemistry has emerged as a new challenge. Fluorination of 3D-printed surfaces is highly desirable in many applications due to chemical inertness, low friction coefficients, antifouling properties, and the potential for selective hydrophobic patterning. Despite sporadic reports, silanization methods have not been optimized for covalent bonding with polymeric resins. As a case study, we tested the silanization of a commercially available (meth)acrylate-based resin (BV-007A) with a fluoroalkyl trichlorosilane. Interestingly, plasma oxidation was unnecessary for silanization of this resin and indeed was ineffective. Solvent-based deposition in a fluorinated oil (FC-40) generated significantly higher contact angles than deposition in ethanol or gas-phase deposition, yielding hydrophobic surfaces with contact angle >110° under optimized conditions. Attenuated total reflectance-Fourier transform infrared spectroscopy indicated that the increase in the contact angle correlated with consumption of a carbonyl moiety, suggesting covalent bonding of silane without plasma oxidation. Consistent with a covalent bond, silanization was resistant to mechanical damage and hydrolysis in methanol and was stable over long-term storage. When tested on a suite of photocrosslinkable resins, this silanization protocol generated highly hydrophobic surfaces (contact angle > 110°) on three resins and moderate hydrophobicity (90-100°) on the remainder. Selective patterning of hydrophobic regions in an open 3D-printed microchannel was possible in combination with simple masking techniques. Thus, this facile fluorination strategy is expected to be applicable for resin-printed materials in a variety of contexts including micropatterning and multiphase microfluidics.

Hydrophilic modification of SLA 3D printed droplet generators by photochemical grafting

Few droplet generators manufactured using desktop stereolithography 3D printers have been reported in the literature. Moreover, 3D printed microfluidic chips are typically hydrophobic, limiting their application to water in oil droplets. Herein, we present designs for concentric and planar 3D printed microfluidic devices suitable for making polymeric microparticles using an off-the-shelf commercial stereolithography printer and resin. The devices consist of a microscope slide, binder clips, and printed components. Channels were modified by an ultraviolet grafting of methacrylic acid to the surface of chips, yielding a hydrophilic coating without modification to the bulk polymer. The water contact angle decreased from 97.0° to 25.4° after grafting. The presence of the coating was confirmed by microscopy and spectroscopy techniques. Polystyrene microparticles in the <100 μm size range were generated with varying molecular weights using the described microfluidic chips. Our work provides a facile method to construct droplet generators from commercial stereolithography printers and resins, and a rapid surface modification technique that has been under-utilized in 3D printed microfluidics. A wide range of microfluidic devices for other applications can be engineered using the methods described.

A versatile method of manufacturing and directly modifying the surfaces of 3D printed microfluidic devices was developed. The device functionality was demonstrated by producing o/w emulsions that yielded polystyrene microspheres.

The Effect of Physical Cues of Biomaterial Scaffolds on Stem Cell Behavior

Stem cells have been sought as a promising cell source in the tissue engineering field due to their proliferative capacity as well as differentiation potential. Biomaterials have been utilized to facilitate the delivery of stem cells in order to improve their engraftment and long-term viability upon implantation. Biomaterials also have been developed as scaffolds to promote stem cell induced tissue regeneration. This review focuses on the latter where the biomaterial scaffold is designed to provide physical cues to stem cells in order to promote their behavior for tissue formation. Recent work that explores the effect of scaffold physical properties, topography, mechanical properties and electrical properties, is discussed. Although still being elucidated, the biological mechanisms, including cell shape, focal adhesion distribution, and nuclear shape, are presented. This review also discusses emerging areas and challenges in clinical translation.

Fabrication of Transparent and Microstructured Superhydrophobic Substrates Using Additive Manufacturing

We report facile one- and two-step processes for the fabrication of transparent ultrahydrophobic surfaces and three-dimensional (3D)-printed superhydrophobic (SH) microstructures, respectively. In the one-step method, polydimethylsiloxane (PDMS) solution is treated thermally at 350 °C for 4 h, while PDMS-soot is generated and deposited on a glass slide to obtain a transparent SH surface without further chemical modification. For the two-step approach, SH surfaces are obtained by incorporating a 3D printing technique with a convenient hydrophobic coating method. Herein, we first 3D-print microstructured substrates with particular surface parameters, which are designed to facilitate a stable gas-trapping Cassie-Baxter (CB) wetting state based on a thermodynamic calculation. We subsequently coat the 3D-printed microstructures with candle soot (CS) or octadecyltrichlorosilane (OTS) solution to make superhydrophobic surfaces with mechanical durability. These surfaces exhibit an ultrahigh static water contact angle (CA, θ ≃ 158 ± 2 and 147 ± 2° for the CS and OTS coating, respectively) and a low roll-off angle for water droplets. Both static and dynamic (in terms of the advancing and receding) contact angles of a water droplet on the fabricated SH surfaces are in good agreement with the theoretical prediction of Cassie-Baxter contact angles. Furthermore, after a one-year-long shelf time, the SH substrates fabricated sustain good superhydrophobicity after ultrasonic water treatment and against several chemical droplets. All of these methods are simple, cost-effective, and highly efficient processes. The processes, design principle, and contact angle measurements presented here are useful for preparing transparent and superhydrophobic surfaces using additive manufacturing, which enables large-scale production and promisingly expands the application scope of utilizing self-cleaning superhydrophobic material.

From 3D to 4D printing: a reactor for photochemical experiments using hybrid polyurethane acrylates for vat-based polymerization and surface functionalization

The vat-based 3D printing of a chemical reactor with flow-meter geometry from an isocyanate-functionalized acrylate monomer followed by post-processing with amino-functionalized photocatalysts is described. This approach results in solvent- and air-stable flow photochemical reactors with UV-A transparent windows that can be applied for photooxygenation and photo redox catalysis.

Introducing Bioinspired Initiator into Resins for In Situ Repairing of 3D-Printed Metallic Structures

Delicate metal parts with superior electrical, mechanical, and thermal properties have attracted a lot of interest, but it is yet challenging to fabricate. Herein, a strategy of making complex metallic structures is developed in this research through integrating a bioinspired catechol-based initiator, dopamine, as an example, into the three-dimensional (3D) printing process followed by the assistance of surface modification. The wealthy catechol groups growing on the polymer enable the metal coating with a high adhesion stability. A series of complex metallic structures were fabricated, such as Ni-Co, Cu, and Ni Eiffel towers, Ag micro-stretching-dominated architecture, and Au auxetic structure. The introduced metal coating enables the 3D-printed objects with multiple classes of functionalities, such as magnetism or high conductivity. In particular, this method allows in situ repairing of the damaged metallic structures, which not only prolongs the lifespan of products but also solves the long-lasting challenge of repairing 3D printing parts. The detailed fabrication and repairing processes of functional metallic parts are presented and discussed. The proposed strategy has great potential in practical applications related to electronics, energy storage, healthcare, and so on.

Laser Direct Writing of Arbitrary Complex Polymer Microstructures by Nitroxide-Mediated Photopolymerization

In this paper, we demonstrate the possibility of generating arbitrary polymer microstructures covalently linked to a first polymer layer by laser direct writing. At the molecular scale, the process relies on nitroxide-mediated photopolymerization triggered by a light-sensitive alkoxyamine. In addition to the proof of concept and examples of achievable structures, including multichemistry patterns and 3D structures, this paper aims at investigating the physicochemical phenomena involved under such conditions. In particular, the parameters influencing the repolymerization process are considered, and special attention is paid to the study of the impact of oxygen on the spatial control of the polymerization. Such a work opens many possibilities toward the fabrication of on-demand high-resolution (multi)functional polymer micro and nanostructures.

3D printing of bioinspired textured surfaces with superamphiphobicity

Natural superwettable surfaces have received extensive attention due to their unique wetting performance and functionalities. Inspired by nature, artificial surfaces with superwettability, particularly superamphiphobicity, i.e., superhydrophobicity and superoleophobicity, have been widely developed using various methods and techniques, where 3D printing, which is also called additive manufacturing, is an emerging technique. 3D printing is efficient for rapid and precise prototyping with the advantage of fabricating various architectures and structures with extreme complexity. Therefore, it is promising for building bioinspired superamphiphobic surfaces with structural complexity in a facile manner. Herein, the state-of-the-art 3D printing techniques and methods for fabricating superwettable surfaces with micro/nanostructures are reviewed, followed by an overview of their extensive applications, which are believed to be promising in engineered wettability, bionic science, liquid transport, microfluidics, drag reduction, anti-fouling, oil/water separation, etc.

3D Printing of an Oil/Water Mixture Separator with In Situ Demulsification and Separation

Currently, many meshes, membranes, and fabrics with extreme wettability of superhydrophobicity/superoleophilicity, or superhydrophilicity and underwater superoleophobicity are promising candidates for oil/water mixture separation. Nevertheless, a facile yet effective way to design and fabricate porous mesh still remains challenging. In this work, fused deposition modeling (FDM) 3D printing of Fe/polylactic acid (PLA) composites was employed to fabricate superhydrophilic and underwater superoleophobic mesh (S-USM) with hydrogel coatings via the surface polymerization of Fe(II)-mediated redox reaction. In addition, salt of aluminum chloride was incorporated within the hydrogel coating, which was attributed to strengthening the demulsification of oil-in-water emulsions, resulting in efficient separation of oil-in-water mixtures. The S-USM was efficient for a wide range of oil-in-water mixtures, such as dodecane, diesel, vegetable oil, and even crude oil, with a separation efficiency of up to 85%. In this study, the flexible design and fabrication of 3D printing were used for the facile creation of spherical oil skimmers with hydrogel coatings that were capable of removing the floating oil. Most importantly, this work is expected to promote post-treatment processes using 3D printing as a new manufacturing technology and, in this way, a series of devices of specific shape and function will be expanded to satisfy desired requirements and bring great convenience to personal life.

Thiol–yne chemistry for 3D printing: exploiting an off-stoichiometric route for selective functionalization of 3D objects

An alkyne monomer, bis(propargyl) fumarate, is synthesized and mixed to a thiol monomer to produce DLP-3D printable formulations. Using off-stoichiometric formulations it is possible to print functionalizable objects.

Bioinspired Ultra-Low Adhesive Energy Interface for Continuous 3D Printing: Reducing Curing Induced Adhesion

Additive manufacturing based on liquid resin curing is one of the most promising methods to construct delicate structures. However, precision and speed are limited by the vertical adhesion of in situ cured resin at the curing interface. To overcome the unavoidable adhesion and to develop a general curing interface, we propose a slippery surface taking inspiration of the peristome surface of the pitcher plant. Such surface shows ultra-low adhesive energy at the curing interface due to the inhibition of the direct contact between the cured resin and the solid surface, which also increases the refilling speed of liquid resin. This ultra-low adhesive energy interface is effective for continuous 3D printing and provides insights into the physical mechanisms in reducing vertical solid-solid interfacial adhesion.

Hierarchical metal/polymer metamaterials of tunable negative Poisson's ratio fabricated by initiator-integrated 3D printing (i3DP)

Metamaterials with artificially designed architectures can achieve unique and even unprecedented physical properties, which show promising applications in actuators, amplifiers and micromechanical controls. An initiator-integrated 3D printing technology (i3DP) was applied in this study to create scalable, metal/polymer meta-mechanical materials, which can gradually achieve negative Poisson's ratio, high strength and ultralow density, as well as high compressive and super-elastic behavior. The i3DP was enabled by integrating an atomic-transfer radical polymerization (ATRP) initiator with UV-curable resin, followed by polyelectrolyte brushes (PMETAC) grafting via surface-initiated ATRP and thereafter electroless plating to form metal coatings. Compared with polymer structures, the compressive stress of metal-polymer structure can be doubled when deposited with a 190 nm copper layer. The hollow metallic materials possess a tunable Poisson's ratio, and the highest average recoverability, which can recover nearly completely to their original shape after over 30% compression. Overall, this i3DP approach provides meta-structures with substantial benefits from the hierarchical design and fabrication flexibility.

Fabrication of a Malaria-Ab ELISA Bioassay Platform with Utilization of Syringe-Based and 3D Printed Assay Automation

We report on the fabrication of a syringe-based platform for automation of a colorimetric malaria-Ab assay. We assembled this platform from inexpensive disposable plastic syringes, plastic tubing, easily-obtainable servomotors, and an Arduino microcontroller chip, which allowed for system automation. The automated system can also be fabricated using stereolithography (SLA) to print elastomeric reservoirs (used instead of syringes), while platform framework, including rack and gears, can be printed with fused deposition modeling (FDM). We report on the optimization of FDM and SLA print parameters, as well as post-production processes. A malaria-Ab colorimetric test was successfully run on the automated platform, with most of the assay reagents dispensed from syringes. Wash solution was dispensed from an SLA-printed elastomeric reservoir to demonstrate the feasibility of both syringe and elastomeric reservoir-based approaches. We tested the platform using a commercially available malaria-Ab colorimetric assay originally designed for spectroscopic plate readers. Unaided visual inspection of the assay solution color change was sufficient for qualitative detection of positive and negative samples. A smart phone application can also be used for quantitative measurement of the assay color change.

Recent Progress in Biomimetic Additive Manufacturing Technology: From Materials to Functional Structures

Nature has developed high-performance materials and structures over millions of years of evolution and provides valuable sources of inspiration for the design of next-generation structural materials, given the variety of excellent mechanical, hydrodynamic, optical, and electrical properties. Biomimicry, by learning from nature's concepts and design principles, is driving a paradigm shift in modern materials science and technology. However, the complicated structural architectures in nature far exceed the capability of traditional design and fabrication technologies, which hinders the progress of biomimetic study and its usage in engineering systems. Additive manufacturing (three-dimensional (3D) printing) has created new opportunities for manipulating and mimicking the intrinsically multiscale, multimaterial, and multifunctional structures in nature. Here, an overview of recent developments in 3D printing of biomimetic reinforced mechanics, shape changing, and hydrodynamic structures, as well as optical and electrical devices is provided. The inspirations are from various creatures such as nacre, lobster claw, pine cone, flowers, octopus, butterfly wing, fly eye, etc., and various 3D-printing technologies are discussed. Future opportunities for the development of biomimetic 3D-printing technology to fabricate next-generation functional materials and structures in mechanical, electrical, optical, and biomedical engineering are also outlined.

Development of ultralight, super-elastic, hierarchical metallic meta-structures with i3DP technology

Lightweight and mechanically robust materials show promising applications in thermal insulation, energy absorption, and battery catalyst supports. This study demonstrates an effective method for creation of ultralight metallic structures based on initiator-integrated 3D printing technology (i3DP), which provides a possible platform to design the materials with the best geometric parameters and desired mechanical performance. In this study, ultralight Ni foams with 3D interconnected hollow tubes were fabricated, consisting of hierarchical features spanning three scale orders ranging from submicron to centimeter. The resultant materials can achieve an ultralight density of as low as 5.1 mg cm^-3 and nearly recover after significant compression up to 50%. Due to a high compression ratio, the hierarchical structure exhibits superior properties in terms of energy absorption and mechanical efficiency. The relationship of structural parameters and mechanical response was established. The ability of achieving ultralight density <10 mg cm^-3 and the stable [Formula: see text] scaling through all range of relative density, indicates an advantage over the previous stochastic metal foams. Overall, this initiator-integrated 3D printing approach provides metallic structures with substantial benefits from the hierarchical design and fabrication flexibility to ultralight applications.

Surface functionalization of 3D-printed plastics via initiated chemical vapor deposition

3D printing is a useful fabrication technique because it offers design flexibility and rapid prototyping. The ability to functionalize the surfaces of 3D-printed objects allows the bulk properties, such as material strength or printability, to be chosen separately from surface properties, which is critical to expanding the breadth of 3D printing applications. In this work, we studied the ability of the initiated chemical vapor deposition (iCVD) process to coat 3D-printed shapes composed of poly(lactic acid) and acrylonitrile butadiene styrene. The thermally insulating properties of 3D-printed plastics pose a challenge to the iCVD process due to large thermal gradients along the structures during processing. In this study, processing parameters such as the substrate temperature and the filament temperature were systematically varied to understand how these parameters affect the uniformity of the coatings along the 3D-printed objects. The 3D-printed objects were coated with both hydrophobic and hydrophilic polymers. Contact angle goniometry and X-ray photoelectron spectroscopy were used to characterize the functionalized surfaces. Our results can enable the use of iCVD to functionalize 3D-printed materials for a range of applications such as tissue scaffolds and microfluidics.

Post-printing surface modification and functionalization of 3D-printed biomedical device

3D printing is a technology well-suited for biomedical applications due to its ability to create highly complex and arbitrary structures from personalized designs with a fast turnaround. However, due to a limited selection of 3D-printable materials, the biofunctionality of many 3D-printed components has not been paid enough attention. In this perspective, we point out that post-3D printing modification is the solution that could close the gap between 3D printing technology and desired biomedical functions. We identify architectural reconfiguration and surface functionalization as the two main post-3D printing modification processes and discuss potential techniques for post-3D printing modification to achieve desired biofunctionality.

Surface-Initiated Controlled Radical Polymerization: State-of-the-Art, Opportunities, and Challenges in Surface and Interface Engineering with Polymer Brushes

The generation of polymer brushes by surface-initiated controlled radical polymerization (SI-CRP) techniques has become a powerful approach to tailor the chemical and physical properties of interfaces and has given rise to great advances in surface and interface engineering. Polymer brushes are defined as thin polymer films in which the individual polymer chains are tethered by one chain end to a solid interface. Significant advances have been made over the past years in the field of polymer brushes. This includes novel developments in SI-CRP, as well as the emergence of novel applications such as catalysis, electronics, nanomaterial synthesis and biosensing. Additionally, polymer brushes prepared via SI-CRP have been utilized to modify the surface of novel substrates such as natural fibers, polymer nanofibers, mesoporous materials, graphene, viruses and protein nanoparticles. The last years have also seen exciting advances in the chemical and physical characterization of polymer brushes, as well as an ever increasing set of computational and simulation tools that allow understanding and predictions of these surface-grafted polymer architectures. The aim of this contribution is to provide a comprehensive review that critically assesses recent advances in the field and highlights the opportunities and challenges for future work.

High-Power 365 nm UV LED Mercury Arc Lamp Replacement for Photochemistry and Chemical Photolithography

Ultraviolet light emitting diodes (UV LEDs) have become widespread in chemical research as highly efficient light sources for photochemistry and photopolymerization. However, in more complex experimental setups requiring highly concentrated light and highly spatially resolved patterning of the light, high-pressure mercury arc lamps are still widely used because they emit intense UV light from a compact arc volume that can be efficiently coupled into optical systems. Advances in the deposition and p-type doping of gallium nitride have recently permitted the manufacture of UV LEDs capable of replacing mercury arc lamps also in these applications. These UV LEDs exceed the spectral radiance of mercury lamps even at the intense I-line at 365 nm. Here we present the successful exchange of a high-pressure mercury arc lamp for a new generation UV LED as a light source in photolithographic chemistry and its use in the fabrication of high-density DNA microarrays. We show that the improved light radiance and efficiency of these LEDs offer substantial practical, economic and ecological advantages, including faster synthesis, lower hardware costs, very long lifetime, an >85-fold reduction in electricity consumption and the elimination of mercury waste and contamination.

Combining additive manufacturing and catalysis: a review

A review on additive manufacturing (AM) applied to heterogeneous catalysis reveals enabling power of AM and challenges to overcome in chemical interfacing and material printability.

3D printed microfluidic devices: enablers and barriers

3D printing has the potential to significantly change the field of microfluidics. The ability to fabricate a complete microfluidic device in a single step from a computer model has obvious attractions, but it is the ability to create truly three dimensional structures that will provide new microfluidic capability that is challenging, if not impossible to make with existing approaches. This critical review covers the current state of 3D printing for microfluidics, focusing on the four most frequently used printing approaches: inkjet (i3DP), stereolithography (SLA), two photon polymerisation (2PP) and extrusion printing (focusing on fused deposition modeling). It discusses current achievements and limitations, and opportunities for advancement to reach 3D printing's full potential.

The upcoming 3D-printing revolution in microfluidics

In the last two decades, the vast majority of microfluidic systems have been built in poly(dimethylsiloxane) (PDMS) by soft lithography, a technique based on PDMS micromolding. A long list of key PDMS properties have contributed to the success of soft lithography: PDMS is biocompatible, elastomeric, transparent, gas-permeable, water-impermeable, fairly inexpensive, copyright-free, and rapidly prototyped with high precision using simple procedures. However, the fabrication process typically involves substantial human labor, which tends to make PDMS devices difficult to disseminate outside of research labs, and the layered molding limits the 3D complexity of the devices that can be produced. 3D-printing has recently attracted attention as a way to fabricate microfluidic systems due to its automated, assembly-free 3D fabrication, rapidly decreasing costs, and fast-improving resolution and throughput. Resins with properties approaching those of PDMS are being developed. Here we review past and recent efforts in 3D-printing of microfluidic systems. We compare the salient features of PDMS molding with those of 3D-printing and we give an overview of the critical barriers that have prevented the adoption of 3D-printing by microfluidic developers, namely resolution, throughput, and resin biocompatibility. We also evaluate the various forces that are persuading researchers to abandon PDMS molding in favor of 3D-printing in growing numbers.

3D-Printed Microfluidics

The advent of soft lithography allowed for an unprecedented expansion in the field of microfluidics. However, the vast majority of PDMS microfluidic devices are still made with extensive manual labor, are tethered to bulky control systems, and have cumbersome user interfaces, which all render commercialization difficult. On the other hand, 3D printing has begun to embrace the range of sizes and materials that appeal to the developers of microfluidic devices. Prior to fabrication, a design is digitally built as a detailed 3D CAD file. The design can be assembled in modules by remotely collaborating teams, and its mechanical and fluidic behavior can be simulated using finite-element modeling. As structures are created by adding materials without the need for etching or dissolution, processing is environmentally friendly and economically efficient. We predict that in the next few years, 3D printing will replace most PDMS and plastic molding techniques in academia.

Three-dimensional printed knotted reactors enabling highly sensitive differentiation of silver nanoparticles and ions in aqueous environmental samples

Whether silver nanoparticles (AgNPs) persist or release silver ions (Ag(+)) when discharged into a natural environment has remained an unresolved issue. In this study, we employed a low-cost stereolithographic three-dimensional printing (3DP) technology to fabricate the angle-defined knotted reactors (KRs) to construct a simple differentiation scheme for quantitative assessment of Ag(+) ions and AgNPs in municipal wastewater samples. We chose xanthan/phosphate-buffered saline as a dispersion medium for in situ stabilization of the two silver species, while also facilitating their extraction from complicated wastewater matrices. After method optimization, we measured extraction efficiencies of 54.5 and 32.3% for retaining Ag(+) ions and AgNPs, respectively, in the printed KR (768-turn), with detection limits (DLs) of 0.86 and 0.52 ng L(-1) when determining Ag(+) ions and AgNPs, respectively (sample run at pH 11 without a rinse solution), and 0.86 ng L(-1) when determining Ag(+) ions alone (sample run at pH 12 with a 1.5-mL rinse solution). The proposed scheme is tolerant of the wastewater matrix and provides more reliable differentiation between Ag(+)/AgNPs than does a conventional filtration method. The concept and applicability of adopting 3DP technology to renew traditional KR devices were evidently proven by means of these significantly improved analytical performance. Our analytical data suggested that the concentrations of Ag(+) ions and AgNPs in the tested industrial wastewater sample were both higher than those in domestic wastewater, implying that industrial activity might be a main source of environmental silver species, rather than domestic discharge from AgNP-containing products.

A lotus root inspired implant system with fever responsive characteristics and 3D printing defined nano-antibiotic release patterns

Lotus root imitated scaffolds were fabricated with several critical releasing parameters could be prearranged. Furthermore, when postoperative infection caused hyperthermia occurred, the inner drugs, could be spontaneously released.

Fully 3D-Printed Preconcentrator for Selective Extraction of Trace Elements in Seawater

In this study, we used a stereolithographic 3D printing technique and polyacrylate polymers to manufacture a solid phase extraction preconcentrator for the selective extraction of trace elements and the removal of unwanted salt matrices, enabling accurate and rapid analyses of trace elements in seawater samples when combined with a quadrupole-based inductively coupled plasma mass spectrometer. To maximize the extraction efficiency, we evaluated the effect of filling the extraction channel with ordered cuboids to improve liquid mixing. Upon automation of the system and optimization of the method, the device allowed highly sensitive and interference-free determination of Mn, Ni, Zn, Cu, Cd, and Pb, with detection limits comparable with those of most conventional methods. The system's analytical reliability was further confirmed through analyses of reference materials and spike analyses of real seawater samples. This study suggests that 3D printing can be a powerful tool for building multilayer fluidic manipulation devices, simplifying the construction of complex experimental components, and facilitating the operation of sophisticated analytical procedures for most sample pretreatment applications.

3D-printed microfluidic automation

Microfluidic automation - the automated routing, dispensing, mixing, and/or separation of fluids through microchannels - generally remains a slowly-spreading technology because device fabrication requires sophisticated facilities and the technology's use demands expert operators. Integrating microfluidic automation in devices has involved specialized multi-layering and bonding approaches. Stereolithography is an assembly-free, 3D-printing technique that is emerging as an efficient alternative for rapid prototyping of biomedical devices. Here we describe fluidic valves and pumps that can be stereolithographically printed in optically-clear, biocompatible plastic and integrated within microfluidic devices at low cost. User-friendly fluid automation devices can be printed and used by non-engineers as replacement for costly robotic pipettors or tedious manual pipetting. Engineers can manipulate the designs as digital modules into new devices of expanded functionality. Printing these devices only requires the digital file and electronic access to a printer.

Three-dimensional printed sample load/inject valves enabling online monitoring of extracellular calcium and zinc ions in living rat brains

We have developed a simple and low-cost flow injection system coupled to a quadruple ICP-MS for the direct and continuous determination of multi-element in microdialysates. To interface microdialysis sampling to an inductively coupled plasma mass spectrometer (ICP-MS), we employed 3D printing to manufacture an as-designed sample load/inject valve featuring an in-valve sample loop for precise handling of microliter samples with a dissolved solids content of 0.9% NaCl (w/v). To demonstrate the practicality of our developed on-line system, we applied the 3D printed valve equipped a 5-μL sample loop to minimize the occurrence of salt matrix effects and facilitate an online dynamic monitoring of extracellular calcium and zinc ions in living rat brains. Under the practical condition (temporal resolution: 10h(-1)), dynamic profiling of these two metal ions in living rat brain extracellular fluid after probe implantation (the basal values for Ca and Zn were 12.11±0.10mg L(-1) and 1.87±0.05μg L(-1), respectively) and real-time monitoring of the physiological response to excitotoxic stress elicited upon perfusing a solution of 2.5mM N-methyl-d-aspartate were performed.

Initiator-integrated 3D printing enables the formation of complex metallic architectures

Three-dimensional printing was used to fabricate various metallic structures by directly integrating a Br-containing vinyl-terminated initiator into the 3D resin followed by surface-initiated atomic-transfer radical polymerization (ATRP) and subsequent electroless plating. Cu- and Ni-coated complex structures, such as microlattices, hollow balls, and even Eiffel towers, were prepared. Moreover, the method is also capable of fabricating ultralight cellular metals with desired structures by simply etching the polymer template away. By combining the merits of 3D printing in structure design with those of ATRP in surface modification and polymer-assisted ELP of metals, this universal, robust, and cost-effective approach has largely extended the capability of 3D printing and will make 3D printing technology more practical in areas of electronics, acoustic absorption, thermal insulation, catalyst supports, and others.