Fabrication and Characterization of Flexible Medical-Grade TPU Filament for Fused Deposition Modeling 3DP Technology

Individualized Design Application of 3-Dimensional Printing Navigational Template for Pedicle Screw Installation: A Training Case Report

BACKGROUND The proper installation for pedicle screws by the traditional method of surgeons dependent on experience is not guaranteed, and educational solutions have progressed from chalkboards to electronic teaching platforms. We designed a case of 3-dimensional printing drill guide template as a surgical application, which can accurately navigate implantation of pedicle screws, and assessed its effect for simulative training. MATERIAL AND METHODS We randomly selected a set of computed tomography data for spondylolisthesis. A navigational template of pedicles and screws was designed by software Mimics and Pro-E, where trajectories of directions and angles guiding the nail way were manipulated for screwing based on anatomy, and its solid model was fabricated by a BT600 3D printer. The screws were integrated and installed to observe their stability. RESULTS The navigational model and custom spine implants were examined to be compatibly immobilized, because they are tolerant to radiation and stable against hydrolysis. The screw size and template were fit accurately to the vertebrae intraosseously, because the pilot holes were drilled and the trajectories were guided by cannulas with visible routes. During the surgical workflow, the patient reported appreciation and showed substantial compliance, while having few complications with this approach. Compared with fluoroscopy-assisted or free-hand techniques, the effect of simulative training during processing was excellent. CONCLUSIONS The surgical biomodel is practical for the procedural accuracy of surgical guides or as an educational drill. This fostering a style of "practice substituting for teaching" sets a paragon of keeping up with time and is worthy of recommendation.

Efficacy of 3D printed anatomically equivalent thermoplastic polyurethane guide conduits in promoting the regeneration of critical-sized peripheral nerve defects

Three-dimensional (3D) printing is an emerging tool for creating patient-specific tissue constructs analogous to the native tissue microarchitecture. In this study, anatomically equivalent 3D nerve conduits were developed using thermoplastic polyurethane (TPU) by combining reverse engineering and material extrusion (i.e. fused deposition modeling) technique. Printing parameters were optimized to fabricate nerve-equivalent TPU constructs. The TPU constructs printed with different infill densities supported the adhesion, proliferation, and gene expression of neuronal cells. Subcutaneous implantation of the TPU constructs for three months in rats showed neovascularization with negligible local tissue inflammatory reactions and was classified as a non-irritant biomaterial as per ISO 10993-6. To performin vivoefficacy studies, nerve conduits equivalent to rat's sciatic nerve were fabricated and bridged in a 10 mm sciatic nerve transection model. After four months of implantation, the sensorimotor function and histological assessments revealed that the 3D printed TPU conduits promoted the regeneration in critical-sized peripheral nerve defects equivalent to autografts. This study proved that TPU-based 3D printed nerve guidance conduits can be created to replicate the complicated features of natural nerves that can promote the regeneration of peripheral nerve defects and also show the potential to be extended to several other tissues for regenerative medicine applications.

Osteogenic Differentiation Capacity of Dental Pulp Stem Cells on 3D Printed Polyurethane/Boric Acid Scaffold

Additive manufacturing is growing in the area of dentistry and orthopedics due to the potential for the fabrication of individual implants. In this study, fused deposition modeling which is the most popular method was used to produce 3D scaffolds having a grid pattern from the polyurethane (PU) filament. Then, this scaffold was coated with boric acid (BA) with the thermionic vacuum arc technique. The microstructure analysis showed the macro-pores having a dimension of ~ 0.16 mm2. The BA coating increased the roughness in adverse decreased the wettability. The presence of BA on the scaffold before and after cell culture was confirmed by FESEM-EDS and ATR-FTIR. The Cell proliferation and osteogenic differentiation capacity of dental pulp stem cells (DPSCs) on uncoated and coated printed 3D PU scaffolds were also investigated. On the third day, cell viability was found to be higher (1.3-fold) in the groups containing BA. However, on the seventh day, the increase in cell proliferation in the PU+BA group was found to be less than in the other groups. According to Ca deposition analysis and Alizarin Red staining, PU+BA increased the calcium accumulation in the cells in both osteogenic induced and non-induced conditions at day 14. According to gene expression analysis, the Runx2 expression was not detected in PU+BA groups with and without differentiation medium (p ≤0.05). The expression of OCN was persistently increased up to 21-fold and 48-fold in cells on PU and PU+BA in osteogenic differentiation medium group after 14 days compared to control group (p ≤0.05). DSPP expression was observed only in PU+BA in osteogenic differentiation medium group. In line with the results that we have obtained, our 3D printed scaffolds have properties to trigger the differentiation of DPSCs cells in terms of osteogenicity.

Soft Self-Regulating Heating Elements for Thermoplastic Elastomer-Based Electronic Skin Applications

Resistive heating elements can be of particular interest for many applications, such as e-skin. In this study, soft heating elements were developed by combining thermoplastic polyurethane (TPU) with carbon black. In contrast to previous studies on thermoplastic polymer-based thermistors, the heating elements could endure elongations above 100%. Due to the high melting point of the TPU and the carbon filler, the thermistors could be heated up to 180°C without significant deformation. The heating elements were extruded on TPU substrates using material extrusion additive manufacturing in one-step process. Self-regulating behavior to control the maximum temperature was achieved with the application of two different voltages (20 and 25 V) and different current thresholds, between 100 and 800 mA. The heating performance was adjusted by changing the geometry of the sensing elements; an increase in cross section resulted in a lower current density and lower temperature. For the heating elements, variation of the additive manufacturing parameters such as offset, layer height, nozzle speed, and extrusion multiplier resulted in a different width/height aspect ratio of the cross section of the extruded lines, affecting the initial resistivity of the thermistor. Orientation of the carbon filler during extrusion process is one reason for the small change of the longitudinal conductivity of the heating elements. The resulting skin with the integrated heating elements allowed the possibility to perform the in situ heating for the localized healing of structural damage, while maintaining the softness required for the application of soft robotic electronic skin.

Polyurethane-Based Nanocomposites for Regenerative Therapies of Cancer Skin Surgery with Low Inflammatory Potential to Healthy Fibroblasts and Keratinocytes In Vitro

Nanocomposites based on thermoplastic polyurethanes (TPUs) filled with halloysite nanotubes (HNTs) were studied for their physicochemical and biological properties. Nanocomposites containing halloysite nanotube filler contents of 1 and 2% (E+1 and E+2), respectively, were obtained by extrusion. The newly formed E+1 and E+2 nanomaterials exhibited better flexibility and similar thermal properties compared to neat polyurethane. The use of atomic force microscopy (AFM) and differential scanning calorimetry (DSC) thermogram analysis showed that the distribution of halloysite nanotubes in the polymer matrix is more evenly dispersed in the E+1 nanomaterial, where the grains in the E+2 nanomaterial have a greater tendency to form agglomerates. Mechanical tests have shown that nanocomposites with the addition of HNT are characterized by a higher stress at break and elongation at break compared to neat TPU. The results of cytotoxicity tests suggest that the nanocomposite materials express lower toxicity to normal HaCaT and NHDF than to cancer Me45 cells. Further studies showed that the tested materials induced the expression of proinflammatory interleukins IL6 and IL8 in normal cells, but their overexpression in the cancer cell line resulted in cytostatic effects and proliferation reduction. Such a conclusion suggests the possible application of tested materials for regenerative therapies in cancer surgeries.

Virtual operation for hip joint replacement implemented by Sensable_FreeForm_Modelling: A surgical drill

OBJECTIVE

To design a virtual operation of joint replacement for surgical drills using a haptic device, SenSable_FreeForm_Modelling (SFM), to enhance surgeons' efficiency and enable "Virtual tutorial without reality" for interns.

METHOD

A patient with hip joint osteoarthritis is randomly selected to perform Total Hip Replacement (THR). The hip images were input into Mimics in the format of *.dicom after CT scan and then exported to SFM using the stereolithographic (*.stl) format. A surgical toolkit can be created virtually with Computer Aided Design software such as Pro-E or Ghost SDK and a visual drill scenario of THR directed by a force-respondent stick, namely Phantom.

RESULT

3D models of the hip joint were rebuilt illustrating clearly that the geometrical shapes of the surgical equipment created are similar to real instruments, and the THR operation is emulated distinctly in novelty.

CONCLUSION

In obedience to an ancient maxim, so called 'genuine knowledge originated from practice', this simulative operation offers hands-on experience for students in the orthopaedics field with remarkable effects, contributing not only teaching cases for medical courses but also a planning basis for physical surgery.

A 5 + 1-Axis 3D Printing Platform for Producing Customized Intestinal Fistula Stents

Tailored intestinal fistula stents with a hollow bent pipe structure prepared by using a three-axis bio-printing platform are often unsuitable due to low printing efficiency and quality caused by the unavoidable need for a supporting structure. Herein, a 5 + 1-axis 3D printing platform was built and developed for producing support-free intestinal fistula stents. A 3D model of the target stent shape and dimensions was treated by a dynamic slicing algorithm, which was then used to prepare a motion control code. Our printing method showed improved printing efficiency, superior stent surface properties and structure and ideal elasticity and mechanical strength to meet the mechanical requirements of the human body. Static simulations showed the importance of axial printing techniques, whereas the stent itself was shown to have excellent biocompatibility with wettability and cell proliferation tests. We present a customizable, efficient, and high-quality method with the potential for preparing bespoke stents for treating intestinal fistulas.

A state-of-the-art guide about the effects of sterilization processes on 3D-printed materials for surgical planning and medical applications: A comparative study

Surgeons use different medical devices in the surgery, such as patient-specific anatomical models, cutting and positioning guides, or implants. These devices must be sterilized before being used in the operation room. There are many sterilization processes available, with autoclave, hydrogen peroxide, and ethylene oxide being the most common in hospital settings. Each method has both advantages and disadvantages in terms of mechanics, chemical interaction, and post-treatment accuracy. The aim of the present study is to evaluate the dimensional and mechanical effect of the most commonly used sterilization techniques available in clinical settings, i.e., Autoclave 121, Autoclave 134, and hydrogen peroxide (HPO), on 11 of the most used 3D-printed materials fabricated using additive manufacturing technologies. The results showed that the temperature (depending on the sterilization method) and the exposure time to that temperature influence not only the mechanical behavior but also the original dimensioning planned on the 3D model. Therefore, HPO is a better overall option for most of the materials evaluated. Finally, based on the results of the study, a recommendation guide on sterilization methods per material, technology, and clinical application is presented.

4D prints of flexible dosage forms using thermoplastic polyurethane with hybrid shape memory effect

Thermoplastic polyurethanes are versatile materials due to their flexible and elastic properties. In research, medicine, and pharmacy, they are used in dosage forms, implants or as components of medical devices. To gain a deeper understanding of the influences on unfolding or expanding dosage forms, in this publication, 3D printing was used to produce differently shaped and foldable objects from various technical thermoplastic polyurethane filaments. The shape memory behaviour of the dosage forms was exploited to fold and package them in water-soluble hard gelatin capsules. The unfolding time and dimensional recovery of the 3D printed dosage forms were investigated as a function of material properties and shape. As an example, for the use of flexible dosage forms, 3D models have been designed so that their unfolded size is suitable for possible gastric retention. Depending on the shape and material, different unfolding behaviours could be shown. Over a storage period of 60 days, a time related stress on the 4D printed objects was evaluated, which possibly affects the unfolding process. The results of this work aim to be used to evaluate the behaviour of 3D printed unfolding and expanding dosage forms and how they may be suitable for the development of innovative sustained drug delivery concepts or medicinal devices. The basic principle of a hybrid shape memory effect used here could possibly be applied to other drug delivery strategies besides gastric retention.

3D-printed microrobots from design to translation

Microrobots have attracted the attention of scientists owing to their unique features to accomplish tasks in hard-to-reach sites in the human body. Microrobots can be precisely actuated and maneuvered individually or in a swarm for cargo delivery, sampling, surgery, and imaging applications. In addition, microrobots have found applications in the environmental sector (e.g., water treatment). Besides, recent advancements of three-dimensional (3D) printers have enabled the high-resolution fabrication of microrobots with a faster design-production turnaround time for users with limited micromanufacturing skills. Here, the latest end applications of 3D printed microrobots are reviewed (ranging from environmental to biomedical applications) along with a brief discussion over the feasible actuation methods (e.g., on- and off-board), and practical 3D printing technologies for microrobot fabrication. In addition, as a future perspective, we discussed the potential advantages of integration of microrobots with smart materials, and conceivable benefits of implementation of artificial intelligence (AI), as well as physical intelligence (PI). Moreover, in order to facilitate bench-to-bedside translation of microrobots, current challenges impeding clinical translation of microrobots are elaborated, including entry obstacles (e.g., immune system attacks) and cumbersome standard test procedures to ensure biocompatibility.

Microbots have attracted attention due to an ability to reach places and perform tasks which are not possible with conventional techniques in a wide range of applications. Here, the authors review the recent work in the field on the fabrication, application and actuation of 3D printed microbots offering a view of the direction of future microbot research.

Anatomically and Biomechanically Relevant Monolithic Total Disc Replacement Made of 3D-Printed Thermoplastic Polyurethane

Various implant treatments, including total disc replacements, have been tried to treat lumbar intervertebral disc (IVD) degeneration, which is claimed to be the main contributor of lower back pain. The treatments, however, come with peripheral issues. This study proposes a novel approach that complies with the anatomical features of IVD, the so-called monolithic total disc replacement (MTDR). As the name suggests, the MTDR is a one-part device that consists of lattice and rigid structures to mimic the nucleus pulposus and annulus fibrosus, respectively. The MTDR can be made of two types of thermoplastic polyurethane (TPU 87A and TPU 95A) and fabricated using a 3D printing approach: fused filament fabrication. The MTDR design involves two configurations—the full lattice (FLC) and anatomy-based (ABC) configurations. The MTDR is evaluated in terms of its physical, mechanical, and cytotoxicity properties. The physical characterization includes the geometrical evaluations, wettability measurements, degradability tests, and swelling tests. The mechanical characterization comprises compressive tests of the materials, an analytical approach using the Voigt model of composite, and a finite element analysis. The cytotoxicity assays include the direct assay using hemocytometry and the indirect assay using a tetrazolium-based colorimetric (MTS) assay. The geometrical evaluation shows that the fabrication results are tolerable, and the two materials have good wettability and low degradation rates. The mechanical characterization shows that the ABC-MTDR has more similar mechanical properties to an IVD than the FLC-MTDR. The cytotoxicity assays prove that the materials are non-cytotoxic, allowing cells to grow on the surfaces of the materials.

Chondro-Inductive b-TPUe-Based Functionalized Scaffolds for Application in Cartilage Tissue Engineering

Osteoarthritis is a disease with a great socioeconomic impact and mainly affects articular cartilage, a tissue with reduced self-healing capacity. In this work, 3D printed 1,4 butanediol thermoplastic polyurethane (b-TPUe) scaffolds are functionalized and infrapatellar mesenchymal stem cells are used as the cellular source. Since b-TPUe is a biomaterial with mechanical properties similar to cartilage, but it does not provide the desired environment for cell adhesion, scaffolds are functionalized with two methods, one based on collagen type I and the other in 1-pyrenebutiric acid (PBA) as principal components. Alamar Blue and confocal assays display that PBA functionalized scaffolds support higher cell adhesion and proliferation for the first 21 days. However, collagen type I functionalization induces higher proliferation rates and similar cell viability than the PBA method. Further, both functionalization methods induce extracellular matrix synthesis, and the presence of chondrogenic markers (Sox9, Col2a, and Acan). Finally, SEM images probe that functionalized 3D printed scaffolds present much better cell/biomaterial interactions than controls and confirm early chondrogenesis. These results indicate that the two methods of functionalization in the highly hydrophobic b-TPUe enhance the cell-biomaterial interactions and the improvement in the chondro-inductive properties, which have great potential for application in cartilage tissue engineering.

Koloor SS, Kumar D, Yahya MY. On Laminated Object Manufactured FDM-Printed ABS/TPU Multimaterial Specimens: An Insight into Mechanical and Morphological Characteristics

Fused deposition modeling (FDM) printing of commercial and reinforced filaments is a proven and well-explored method for the enhancement of mechanical properties. However, little has hitherto been reported on the multi-material components, fused or laminated together into a single specimen by using the laminated object manufacturing (LOM) technique for sustainable/renewable polymers. TPU is one such durable and flexible, sustainable material exhibiting renewable and biocompatible properties that have been explored very less often in combination with the ABS polymer matrix in a single specimen, such as the LOM specimen. The current research work presents the LOM manufacturing of 3D-printed flexural specimens of two different, widely used polymers available viz. ABS and TPU and tested as per ASTM D790 standards. The specimens were made and laminated in three layers. They were grouped into two categories, namely ABS: TPU: ABS (ATA) and TPU: ABS: TPU (TAT), which are functionally graded, sandwiched structures of polymeric material. The investigation of the flexural properties, microscopic imaging, and porosity characteristics of the specimens was made for the above categories. The results of the study suggest that ATA-based samples held larger flexural strength than TAT laminated manufactured samples. A significant improvement in the peak elongation and break elongation of the samples was achieved and has shown a 187% increase in the break elongation. Similarly, for the TAT-based specimen, flexural strength was improved significantly from approximately 6.8 MPa to 13 MPa, which represents a nearly 92% increase in the flexural strength. The morphological testing using Tool Maker’s microscopic analysis and porosity analysis has supported the observed trends of mechanical behavior of ATA and TAT samples.

TPU-based porous heterostructures by combined techniques

The production of thermoplastic polyurethane-based porous heterostructures combining physical foaming with fused deposition modeling is detailed in this contribution. The choice of combining these two techniques lies in the possibility of creating objects endowed with a dual-scale structure at millimeter scale by fused deposition modeling and at microscopic scale by gas foaming. Thermal stability and rheological properties of the neat polymer were studied prior to foaming to design a suitable processing protocol and three different combined techniques are proposed: pressure quench, temperature rise and direct 3D foam printing. Foam morphologies were evaluated by SEM and foamed samples were characterized by thermal and mechanical analyses to highlight the differences among the combined processing techniques. Samples foamed via pressure quench exhibit the highest degree of crystallinity and a uniform cell morphology, also resulting in the largest stiffness. The results presented in this contribution open up the possibility of producing objects with complex geometry and porosity architecture at the dual scale.

Flexible PBAT-Based Composite Filaments for Tunable FDM 3D Printing

Biobased composites with peculiar properties offer an attractive route for producing environmentally friendly materials. The reinforcement for poly(butylene adipate-co-terephthalate) (PBAT), based on zein-titanium dioxide (TiO₂) complex (ZTC) microparticles, is presented and used to produce composite filaments, successfully 3-dimensionally (3D) printed by fused deposition modeling (FDM). The outcome of ZTC addition, ranging from 5 to 40 wt %, on the thermo-mechanical properties of composite materials was analyzed. Results reveal that storage modulus increased with increasing the ZTC content, leading to a slight increase in the glass transition temperature. The creep compliance varies with the ZTC concentration, denoting a better resistance to deformation under constant stress conditions for composites with higher complex content. Scanning electron microscopy was used to assess the quality of interphase adhesion between PBAT and ZTC, showing good dispersion and distribution of complex microparticles in the polymer matrix. Infrared spectroscopy confirmed the formation of a valid interface due to the formation of hydrogen bonds between filler and polymer matrix. Preliminary tests on the biocompatibility of these materials were also performed, showing no cytotoxic effects on cell viability. Finally, the 3D printability of biobased composites was demonstrated by realizing complex structures with a commercial FDM printer.

Use of Polyesters in Fused Deposition Modeling for Biomedical Applications

In recent years, 3D printing techniques experienced a growing interest in several sectors, including the biomedical one. Their main advantage resides in the possibility to obtain complex and personalized structures in a cost-effective way impossible to achieve with traditional production methods. This is especially true for Fused Deposition Modeling (FDM), one of the most diffused 3D printing methods. The easy customization of the final products' geometry, composition and physico-chemical properties is particularly interesting for the increasingly personalized approach adopted in modern medicine. Thermoplastic polymers are the preferred choice for FDM applications, and a wide selection of biocompatible and biodegradable materials is available to this aim. Moreover, these polymers can also be easily modified before and after printing to better suit the body environment and the mechanical properties of biological tissues. This review focuses on the use of thermoplastic aliphatic polyesters for FDM applications in the biomedical field. In detail, the use of poly(ε-caprolactone), poly(lactic acid), poly(lactic-co-glycolic acid), poly(hydroxyalkanoate)s, thermo-plastic poly(ester urethane)s and their blends has been thoroughly surveyed, with particular attention to their main features, applicability and workability. The state-of-the-art is presented and current challenges in integrating the additive manufacturing technology in the medical practice are discussed. This article is protected by copyright. All rights reserved.

Recycling of Waste Cotton Textile Containing Elastane Fibers through Dissolution and Regeneration

Increasing utilization of textiles has raised concern regarding the environmental impact brought by the textile manufacturing process and disposal of waste textiles. In our previous work, the dissolution of cotton waste through different solvent systems was demonstrated. Herein, this study aimed to further investigate the recycling of waste cotton–elastane fabrics using H₂SO₄, NaOH/urea, and LiCl/DMAc solvent systems. The structure of regenerated films was characterized with Fourier transform infrared spectroscopy and scanning electron microscopy, and the properties of the regenerated films, including transparency, mechanical properties, water vapor permeability, and thermal stability, were investigated. The results revealed that all solvent systems could convert the waste cotton–elastane fabrics into regenerated films with the existence of different forms of elastane components. The elastane fibers were partially hydrolyzed in H₂SO₄ solvent and reduced the transparency of regenerated films, but they were well retained in NaOH/urea solvent and interrupted the structure of regenerated cellulose films. It is worth noting that the elastane fibers were completely dissolved in LiCl/DMAc solvent and formed a composite structure with cellulose, leading to obviously improved tensile strength (from 51.00 to 121.63 MPa) and water barrier property (from 3.50 × 10⁻⁷ to 1.03 × 10⁻⁷ g m⁻¹ h⁻¹ Pa⁻¹). Therefore, this work demonstrates the possibility to directly recycle waste cotton–elastane fabrics through dissolution and regeneration, and the resultant films have potential applications as packaging materials.

The Role of 3D Printing in Planning Complex Medical Procedures and Training of Medical Professionals-Cross-Sectional Multispecialty Review

Medicine is a rapidly-evolving discipline, with progress picking up pace with each passing decade. This constant evolution results in the introduction of new tools and methods, which in turn occasionally leads to paradigm shifts across the affected medical fields. The following review attempts to showcase how 3D printing has begun to reshape and improve processes across various medical specialties and where it has the potential to make a significant impact. The current state-of-the-art, as well as real-life clinical applications of 3D printing, are reflected in the perspectives of specialists practicing in the selected disciplines, with a focus on pre-procedural planning, simulation (rehearsal) of non-routine procedures, and on medical education and training. A review of the latest multidisciplinary literature on the subject offers a general summary of the advances enabled by 3D printing. Numerous advantages and applications were found, such as gaining better insight into patient-specific anatomy, better pre-operative planning, mock simulated surgeries, simulation-based training and education, development of surgical guides and other tools, patient-specific implants, bioprinted organs or structures, and counseling of patients. It was evident that pre-procedural planning and rehearsing of unusual or difficult procedures and training of medical professionals in these procedures are extremely useful and transformative.

Computer vision-aided bioprinting for bone research

Bioprinting is an emerging additive manufacturing technology that has enormous potential in bone implantation and repair. The insufficient accuracy of the shape of bioprinted parts is a primary clinical barrier that prevents widespread utilization of bioprinting, especially for bone design with high-resolution requirements. During the last five years, the use of computer vision for process control has been widely practiced in the manufacturing field. Computer vision can improve the performance of bioprinting for bone research with respect to various aspects, including accuracy, resolution, and cell survival rate. Hence, computer vision plays a substantial role in addressing the current defect problem in bioprinting for bone research. In this review, recent advances in the application of computer vision in bioprinting for bone research are summarized and categorized into three groups based on different defect types: bone scaffold process control, deep learning, and cell viability models. The collection of printing parameters, data processing, and feedback of bioprinting information, which ultimately improves printing capabilities, are further discussed. We envision that computer vision may offer opportunities to accelerate bioprinting development and provide a new perception for bone research.

Promoters for Improved Adhesion Strength between Addition-Cured Liquid Silicone Rubber and Low-Melting-Point Thermoplastic Polyurethanes

A polydimethylsiloxane armed with epoxy, alkoxy and acrylate groups was synthesized from silanol terminated-PDMS and epoxy and acrylate groups functionalized silane coupling agents, and utilized as the adhesion promoter (AP) to prepare addition-cured liquid silicone rubber that exhibited self-adhesion ability (SA-LSR) with biocompatible thermoplastic polyurethanes (TPU) sheets. The structural characteristics of AP were characterized by Fourier transform infrared (FTIR) spectroscopy, which demonstrated the strong adhesion to polyester-based TPU sheets due to a sufficient amount of acrylate groups, epoxy groups and silanol groups obtained by the hydrolysis of alkoxy groups. In detail, the peel-off strength of SA-LSR and TPU joints reached up to 7.63 N mm⁻¹ after the optimization of adhesion promoter including type and content, and curing condition including time and temperature. The cohesive failure was achieved during the sample breakage process. Moreover, the SA-LSR showed a good storage stability under proper storage conditions. This design strategy provided the feasibility to combine the advantages of addition-cured liquid silicone rubber and plastics with low melting points, promoting the potential application range of those silicone-based materials.

Design of Customized TPU Lattice Structures for Additive Manufacturing: Influence on the Functional Properties in Elastic Products

This work focuses on evaluating and establishing the relationship of the influence of geometrical and manufacturing parameters in stiffness of additively manufactured TPU lattice structures. The contribution of this work resides in the creation of a methodology that focuses on characterizing the behavior of elastic lattice structures. Likewise, resides in the possibility of using the statistical treatment of results as a guide to find favorable possibilities within the range of parameters studied and to predict the behavior of the structures. In order to characterize their behavior, different types of specimens were designed and tested by finite element simulation of a compression process using Computer Aided Engineering (CAE) tools. The tests showed that the stiffness depends on the topology of the cells of the lattice structure. For structures with different cell topologies, it has been possible to obtain an increase in the reaction force against compression from 24.7 N to 397 N for the same manufacturing conditions. It was shown that other parameters with a defined influence on the stiffness of the structure were the temperature and the unit size of the cells, all due to the development of fusion mechanisms and the variation in the volume of material used, respectively.

Fabrication of a Soft Robotic Gripper With Integrated Strain Sensing Elements Using Multi-Material Additive Manufacturing

With the purpose of making soft robotic structures with embedded sensors, additive manufacturing techniques like fused deposition modeling (FDM) are popular. Thermoplastic polyurethane (TPU) filaments, with and without conductive fillers, are now commercially available. However, conventional FDM still has some limitations because of the marginal compatibility with soft materials. Material selection criteria for the available material options for FDM have not been established. In this study, an open-source soft robotic gripper design has been used to evaluate the FDM printing of TPU structures with integrated strain sensing elements in order to provide some guidelines for the material selection when an elastomer and a soft piezoresistive sensor are combined. Such soft grippers, with integrated strain sensing elements, were successfully printed using a multi-material FDM 3D printer. Characterization of the integrated piezoresistive sensor function, using dynamic tensile testing, revealed that the sensors exhibited good linearity up to 30% strain, which was sufficient for the deformation range of the selected gripper structure. Grippers produced using four different TPU materials were used to investigate the effect of the Shore hardness of the TPU on the piezoresistive sensor properties. The results indicated that the in situ printed strain sensing elements on the soft gripper were able to detect the deformation of the structure when the tentacles of the gripper were open or closed. The sensor signal could differentiate between the picking of small or big objects and when an obstacle prevented the tentacles from opening. Interestingly, the sensors embedded in the tentacles exhibited good reproducibility and linearity, and the sensitivity of the sensor response changed with the Shore hardness of the gripper. Correlation between TPU Shore hardness, used for the gripper body and sensitivity of the integrated in situ strain sensing elements, showed that material selection affects the sensor signal significantly.

3D Printing of Thermoplastic Elastomers: Role of the Chemical Composition and Printing Parameters in the Production of Parts with Controlled Energy Absorption and Damping Capacity

Additive manufacturing (AM) is a disruptive technology that enables one to manufacture complex structures reducing both time and manufacturing cost. Among the materials commonly used for AM, thermoplastic elastomers (TPE) are of high interest due to their energy absorption capacity, energy efficiency, cushion factor or damping capacity. Previous investigations have exclusively focused on the optimization of the printing parameters of commercial TPE filaments and the structures to analyse the mechanical properties of the 3D printed parts. In the present paper, the chemical, thermal and mechanical properties for a wide range of commercial thermoplastic polyurethanes (TPU) filaments were investigated. For this purpose, TGA, DSC, ¹H-NMR and filament tensile strength experiments were carried out in order to determine the materials characteristics. In addition, compression tests have been carried out to tailor the mechanical properties depending on the 3D printing parameters such as: infill density (10, 20, 50, 80 and 100%) and infill pattern (gyroid, honeycomb and grid). The compression tests were also employed to calculate the specific energy absorption (SEA) and specific damping capacity (SDC) of the materials in order to establish the role of the chemical composition and the geometrical characteristics (infill density and type of infill pattern) on the final properties of the printed part. As a result, optimal SEA and SDC performances were obtained for a honeycomb pattern at a 50% of infill density.

Mechanical Properties and In Vitro Evaluation of Thermoplastic Polyurethane and Polylactic Acid Blend for Fabrication of 3D Filaments for Tracheal Tissue Engineering

Surgical reconstruction of extensive tracheal lesions is challenging. It requires a mechanically stable, biocompatible, and nontoxic material that gradually degrades. One of the possible solutions for overcoming the limitations of tracheal transplantation is a three-dimensional (3D) printed tracheal scaffold made of polymers. Polymer blending is one of the methods used to produce material for a trachea scaffold with tailored characteristics. The purpose of this study is to evaluate the mechanical and in vitro properties of a thermoplastic polyurethane (TPU) and polylactic acid (PLA) blend as a potential material for 3D printed tracheal scaffolds. Both materials were melt-blended using a single screw extruder. The morphologies (as well as the mechanical and thermal characteristics) were determined via scanning electron microscopy (SEM), Fourier Transform Infrared (FTIR) spectroscopy, tensile test, and Differential Scanning calorimetry (DSC). The samples were also evaluated for their water absorption, in vitro biodegradability, and biocompatibility. It is demonstrated that, despite being not miscible, TPU and PLA are biocompatible, and their promising properties are suitable for future applications in tracheal tissue engineering.

Influence of 3D-Printed TPU Properties for the Design of Elastic Products

The design of products with elastic properties is a paradigm for design engineers because the properties of the material define the correct functionality of the product. Fused filament fabrication (FFF) allows for the printing of products in thermoplastic polyurethanes (TPU). Therefore, it offers the ability to design elastic products with the freedom of forms that this technology allows and also with greater variation of elastic properties than with a conventional process. The internal structures and the variation in thickness that can be used facilitate the design of products with different elastic realities, producing variations in the elasticity of the product with the same material. This work studies the influence of the variation of internal density as a function of basic geometries in order to quantify the difference in elasticity produced on a product when it is designed. Likewise, a case study was carried out with the creation of a fully elastic computer keyboard printed in 3D. The specimens were subjected to compression to characterize the behavior of the structures. The tests showed that the elasticity varies depending on the orientation and geometry, with the highest compressive strength observed in the vertical orientation with 80% lightening. In addition, the internal lightening increases the elasticity progressively but not uniformly with respect to the solid geometry, and also the flat faces favour the reduction in elasticity. This study classifies the behavior of TPU with the aim of being applied to the design and manufacture of products with specific properties. In this work, a totally flexible and functional keyboard was designed, obtaining elasticity values that validate the study carried out.

Additive Manufacturing of Flexible Material for Pneumatic Actuators Application

In this paper, endurance of peristaltic linear pneumatic actuators was studied using different hose geometries. Towards this goal, different hose geometries were additively manufactured using Fused Layer Manufacturing techniques of Thermoplastic Polyurethane Elastomer. Material properties of the elastomer were studied using Differential Scanning Calorimetry and the tensile test. The relations between the sample’s print temperature and build direction on the actuator endurance were investigated. Lastly, the relation between the geometry design of the PLPA actuator and its endurance is also discussed. Based on this methodology, authors present results showing that the use of a customized shaped hose with geometrical reinforcement at sides leads to a considerable rise in the hose endurance, when compared with the conventional circular design.

Influence of the Halloysite Nanotube (HNT) Addition on Selected Mechanical and Biological Properties of Thermoplastic Polyurethane

Halloysite nanotube (HNT) additions to the thermoplastic polyurethane (TPU) system were thoroughly evaluated in this study. The resultant composites have been designed for future personalized intervertebral disc implant applications, which requires additional technology to obtain the appropriate geometry unique to each patient. These requirements can be fulfilled using 3D printing. In this work, a technology was developed to produce filaments for fused deposition modeling (FDM). Nanocomposites were prepared using variable HNT content (1, 2, and 3 wt.%). The nanostructure of the resultant composites was confirmed using scanning transmission electron microscopy (STEM). Mechanical tests were used to measure the tensile modulus, stress, and elongation the composites and TPU matrix. Nanocomposites with 2% HNT content were able to withstand 26% increased stress and 50% increased elongation compared to pure TPU before fracturing in addition to a 13% reduction in the friction coefficient. A MTT cytotoxicity assay confirmed the cytotoxicity of all tested materials against human epidermal keratinocyte cells (HaCaT).

Optimisation of Strength Properties of FDM Printed Parts-A Critical Review

Additive Manufacturing is currently growing fast, especially fused deposition modeling (FDM), also known as fused filament fabrication (FFF). When manufacturing parts use FDM, there are two key parameters—strength of the part and dimensional accuracy—that need to be considered. Although FDM is a popular technology for fabricating prototypes with complex geometry and other part product with reduced cycle time, it is also limited by several drawbacks including inadequate mechanical properties and reduced dimensional accuracy. It is evident that part qualities are greatly influenced by the various process parameters, therefore an extensive review of the effects of the following process parameters was carried out: infill density, infill patterns, extrusion temperature, layer thickness, nozzle diameter, raster angle and build orientation on the mechanical properties. It was found from the literature that layer thickness is the most important factor among the studied ones. Although manipulation of process parameters makes significant differences in the quality and mechanical properties of the printed part, the ideal combination of parameters is challenging to achieve. Hence, this study also includes the influence of pre-processing of the printed part to improve the part strength and new research trends such as, vacuum-assisted FDM that has shown to improve the quality of the printing due to improved bonding between the layers. Advances in materials and technologies that are currently under development are presented. For example, the pre-deposition heating method, using an IR lamp of other technologies, shows a positive impact on the mechanical properties of the printed parts.

Cellulose and Graphene Based Polyurethane Nanocomposites for FDM 3D Printing: Filament Properties and Printability

3D printing has exponentially grown in popularity due to the personalization of each printed part it offers, making it extremely beneficial for the very demanding biomedical industry. This technique has been extensively developed and optimized and the advances that now reside in the development of new materials suitable for 3D printing, which may open the door to new applications. Fused deposition modeling (FDM) is the most commonly used 3D printing technique. However, filaments suitable for FDM must meet certain criteria for a successful printing process and thus the optimization of their properties in often necessary. The aim of this work was to prepare a flexible and printable polyurethane filament parting from a biocompatible waterborne polyurethane, which shows potential for biomedical applications. In order to improve filament properties and printability, cellulose nanofibers and graphene were employed to prepare polyurethane based nanocomposites. Prepared nanocomposite filaments showed altered properties which directly impacted their printability. Graphene containing nanocomposites presented sound enough thermal and mechanical properties for a good printing process. Moreover, these filaments were employed in FDM to obtained 3D printed parts, which showed good shape fidelity. Properties exhibited by polyurethane and graphene filaments show potential to be used in biomedical applications.

Smartphone-Addressable 3D-Printed Electrochemical Ring for Nonenzymatic Self-Monitoring of Glucose in Human Sweat

Nowadays, there is increased demand for wearable sensors for sweat glucose monitoring in order to facilitate diabetes management in a patient-friendly and noninvasive manner. This work describes a wearable glucose monitoring device in the form of an electrochemical ring (e-ring) fabricated by 3D printing. The 3D-printed e-ring consists of three carbon-based plastic electrodes (fabricated using a conductive filament) integrated at the inner side of a ring-shaped flexible plastic holder (fabricated using a nonconductive filament). The e-ring is modified with an electrodeposited gold film and is coupled to a miniature potentiostat directly addressable by a smartphone, offering the possibility for nonenzymatic amperometric self-testing of glucose levels in human sweat. Optical and electrochemical techniques are employed for the characterization of the e-ring. The device is resistant to mechanical bending and enables noninvasive glucose detection in sweat in the physiologically relevant concentration range of 12.5-400 μmol L^-1 without interference from common electroactive metabolites. The 3D-printed e-ring bridges the gap between the existing fabrication/sensing technologies and the desired operational features for glucose self-monitoring and may be employed as a paradigm of in-house fabricated wearable sensors.

Next-generation surgical meshes for drug delivery and tissue engineering applications: materials, design and emerging manufacturing technologies

Abstract

Surgical meshes have been employed in the management of a variety of pathological conditions including hernia, pelvic floor dysfunctions, periodontal guided bone regeneration, wound healing and more recently for breast plastic surgery after mastectomy. These common pathologies affect a wide portion of the worldwide population; therefore, an effective and enhanced treatment is crucial to ameliorate patients’ living conditions both from medical and aesthetic points of view. At present, non-absorbable synthetic polymers are the most widely used class of biomaterials for the manufacturing of mesh implants for hernia, pelvic floor dysfunctions and guided bone regeneration, with polypropylene and poly tetrafluoroethylene being the most common. Biological prostheses, such as surgical grafts, have been employed mainly for breast plastic surgery and wound healing applications. Despite the advantages of mesh implants to the treatment of these conditions, there are still many drawbacks, mainly related to the arising of a huge number of post-operative complications, among which infections are the most common. Developing a mesh that could appropriately integrate with the native tissue, promote its healing and constructive remodelling, is the key aim of ongoing research in the area of surgical mesh implants. To this end, the adoption of new biomaterials including absorbable and natural polymers, the use of drugs and advanced manufacturing technologies, such as 3D printing and electrospinning, are under investigation to address the previously mentioned challenges and improve the outcomes of future clinical practice. The aim of this work is to review the key advantages and disadvantages related to the use of surgical meshes, the main issues characterizing each clinical procedure and the future directions in terms of both novel manufacturing technologies and latest regulatory considerations.

Graphic abstract

Enhancement of High-Resolution 3D Inkjet-Printing of Optical Freeform Surfaces Using Digital Twins

3D-inkjet-printing is just beginning to take off in the optical field. Advantages of this technique include its fast and cost-efficient fabrication without tooling costs. However, there are still obstacles preventing 3D inkjet-printing from a broad usage in optics, e.g., insufficient form fidelity. In this article, we present the formulation of a digital twin by the enhancement of an optical model by integrating geometrical measurement data. This approach strengthens the high-precision 3D printing process to fulfil optical precision requirements. A process flow between the design of freeform components, fabrication by inkjet printing, the geometrical measurement of the fabricated optical surface, and the feedback of the measurement data into the simulation model was developed, and its interfaces were defined. The evaluation of the measurements allowed for the adaptation of the printing process to compensate for process errors and tolerances. Furthermore, the performance of the manufactured component was simulated and compared with the nominal performance, and the enhanced model could be used for sensitivity analysis. The method was applied to a highly complex helical surface that allowed for the adjustment of the optical power by rotation. We show that sensitivity analysis could be used to define acceptable tolerance budgets of the process.

Processing of Polyester-Urethane Filament and Characterization of FFF 3D Printed Elastic Porous Structures with Potential in Cancellous Bone Tissue Engineering

This paper addresses the potential of self-made polyester-urethane filament as a candidate for Fused Filament Fabrication (FFF)-based 3D printing (3DP) in medical applications. Since the industry does not provide many ready-made solutions of medical-grade polyurethane filaments, we undertook research aimed at presenting the process of thermoplastic polyurethane (TPU) filament formation, detailed characteristics, and 3DP of specially designed elastic porous structures as candidates in cancellous tissue engineering. Additionally, we examined whether 3D printing affects the structure and thermal stability of the filament. According to the obtained results, the processing parameters leading to the formation of high-quality TPU filament (TPU_F) were captured. The results showed that TPU_F remains stable under the FFF 3DP conditions. The series of in vitro studies involving long- and short-term degradation (0.1 M phosphate-buffered saline (PBS); 5 M sodium hydroxide (NaOH)), cytotoxicity (ISO 10993:5) and bioactivity (simulated body fluid (SBF) incubation), showed that TPU printouts possessing degradability of long-term degradable tissue constructs, are biocompatible and susceptible to mineralization in terms of hydroxyapatite (HAp) formation during SBF exposure. The formation of HAp on the surface of the specially designed porous tissue structures (PTS) was confirmed by scanning electron microscope (SEM) and energy-dispersive X-ray spectroscopy (EDS) studies. The compression test of PTS showed that the samples were strengthened due to SBF exposure and deposited HAp on their surface. Moreover, the determined values of the tensile strength (~30 MPa), Young’s modulus (~0.2 GPa), and compression strength (~1.1 MPa) allowed pre-consideration of TPU_F for FFF 3DP of cancellous bone tissue structures.

Deformation Process of 3D Printed Structures Made from Flexible Material with Different Values of Relative Density

The main aim of this article is the analysis of the deformation process of regular cell structures under quasi-static load conditions. The methodology used in the presented investigations included a manufacturability study, strength tests of the base material as well as experimental and numerical compression tests of developed regular cellular structures. A regular honeycomb and four variants with gradually changing topologies of different relative density values have been successfully designed and produced in the TPU-Polyflex flexible thermoplastic polyurethane material using the Fused Filament Fabrication (FFF) 3D printing technique. Based on the results of performed technological studies, the most productive and accurate 3D printing parameters for the thermoplastic polyurethane filament were defined. It has been found that the 3D printed Polyflex material is characterised by a very high flexibility (elongation up to 380%) and a non-linear stress-strain relationship. A detailed analysis of the compression process of the structure specimens revealed that buckling and bending were the main mechanisms responsible for the deformation of developed structures. The Finite Element (FE) method and Ls Dyna software were used to conduct computer simulations reflecting the mechanical response of the structural specimens subjected to a quasi-static compression load. The hyperelastic properties of the TPU material were described with the Simplified Rubber Material (SRM) constitutive model. The proposed FE models, as well as assumed initial boundary conditions, were successfully validated. The results obtained from computer simulations agreed well with the data from the experimental compression tests. A linear relationship was found between the relative density and the maximum strain energy value.

Urogynecological surgical mesh implants: New trends in materials, manufacturing and therapeutic approaches

Pelvic Organ Prolapse (POP) and Stress Urinary Incontinence (SUI) are two prevalent disorders affecting 30-40% of women worldwide. Current strategies to repair or improve these medical conditions are non-surgical options such as physiotherapy, or surgical options such as the use of vaginal meshes. The synthetic material polypropylene (PP), which has long been used for manufacturing these vaginal meshes, is associated with severe complications such as chronic pain, infection or mesh erosion. As a result of a widespread reporting and unacceptably high rates of complications, these issues have become a public health concern. Regulatory bodies have recently deemed the transvaginal placement of PP mesh in the pelvic floor (PF) no longer a suitable treatment method for PF repair, leading to the need for a novel approach to the manufacture and selection of materials for urogynecological meshes. Medical devices, such as vaginal meshes can be manufactured using a variety of techniques including injection moulding, electrospinning, hot-melt extrusion (HME) or more recently 3D printing. Over the past decade, the use of 3D printing within the medical device industry has expanded and offers a promising approach to manufacture patient-specific surgical mesh when combined with imaging tools. This review will summarise the current strategies to treat POP and SUI, the issues and use of current meshes for the treatment of these pelvic floor disorders (PFDs), and the future directions for the manufacture of more suitable urogynecological meshes, as well as their potential materials.

Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing

This article reports on the investigation of the effects of process parameters and their interactions on as-built part quality and resource-efficiency of the fused filament fabrication 3D printing process. In particular, the influence of five process parameters: infill percentage, layer thickness, printing speed, printing temperature, and surface inclination angle on dimensional accuracy, surface roughness of the built part, energy consumption, and productivity of the process was examined using Taguchi orthogonal array (L50) design of experiment. The experimental results were analyzed using ANOVA and statistical analysis, and the parameters for optimal responses were identified. Regression models were developed to predict different process responses in terms of the five process parameters experimentally examined in this study. It was found that dimensional accuracy is negatively influenced by high values of layer thickness and printing speed, since thick layers of printed material tend to spread out and high printing speeds hinder accurate deposition of the printed material. In addition, the printing temperature, which regulates the viscosity of the used material, plays a significant role and helps to minimize the dimensional error caused by thick layers and high printing speeds, whereas the surface roughness depends very much on surface inclination angle and layer thickness, which together determine the influence of the staircase effect. Energy consumption and productivity are primarily affected by printing speed and layer thickness, due to their high correlation with build time.

Novel Synthesis of Core-Shell Biomaterials from Polymeric Filaments with a Bioceramic Coating for Biomedical Applications

Bone tissue engineering is constantly in need of new material development with improved biocompatibility or mechanical features closer to those of natural bone. Other important factors are the sustainability, cost, and origin of the natural precursors involved in the technological process. This study focused on two widely used polymers in tissue engineering, namely polylactic acid (PLA) and thermoplastic polyurethane (TPU), as well as bovine-bone-derived hydroxyapatite (HA) for the manufacturing of core-shell structures. In order to embed the ceramic particles on the polymeric filaments surface, the materials were introduced in an electrical oven at various temperatures and exposure times and under various pressing forces. The obtained core-shell structures were characterized in terms of morphology and composition, and a pull-out test was used to demonstrate the particles adhesion on the polymeric filaments structure. Thermal properties (modulated temperature and exposure time) and the pressing force’s influence upon HA particles’ insertion degree were evaluated. More to the point, the form variation factor and the mass variation led to the optimal technological parameters for the synthesis of core-shell materials for prospect additive manufacturing and regenerative medicine applications.

Fused Deposition Modeling as an Effective Tool for Anti-Infective Dialysis Catheter Fabrication

Catheter-associated infections are a common complication that occurs in dialysis patients. Current strategies to prevent infection include catheter coatings containing heparin, pyrogallol, or silver nanoparticles, which all have an increased risk of causing resistance in bacteria. Therefore, a novel approach for manufacture, such as the use of additive manufacturing (AM), also known as three-dimensional (3D) printing, is required. Filaments were produced by extrusion using thermoplastic polyurethane (TPU) and tetracycline hydrochloride (TC) in various concentrations (e.g., 0, 0.25, 0.5, and 1%). The extruded filaments were used in a fused deposition modeling (FDM) 3D printer to print catheter constructs at varying concentrations. Release studies in phosphate-buffered saline, microbiology studies, thermal analysis, contact angle, attenuated total reflection-Fourier transform infrared, scanning electron microscopy, and X-ray microcomputer tomography (μCT) analysis were conducted on the printed catheters. The results suggested that TC was uniformly distributed within the TPU matrix. The microbiology testing of the catheters showed that devices containing TC had an inhibitory effect on the growth of Staphylococcus aureus NCTC 10788 bacteria. Catheters containing 1% TC maintained inhibitory effect after 10 day release studies. After an initial burst release in the first 24 h, there was a steady release of TC in all concentrations of catheters. 3D-printed antibiotic catheters were successfully printed with inhibitory effect on S. aureus bacteria. Finally, TC containing catheters showed resistance to S. aureus adherence to their surfaces when compared with catheters containing no TC. Catheters containing 1% of TC showed a bacterial adherence reduction of up to 99.97%. Accordingly, the incorporation of TC to TPU materials can be effectively used to prepare anti-infective catheters using FDM. This study highlights the potential for drug-impregnated medical devices to be created through AM.

Fused Deposition Modelling as a Potential Tool for Antimicrobial Dialysis Catheters Manufacturing: New Trends vs. Conventional Approaches

The rising rate of individuals with chronic kidney disease (CKD) and ineffective treatment methods for catheter-associated infections in dialysis patients has led to the need for a novel approach to the manufacturing of catheters. The current process requires moulding, which is time consuming, and coated catheters used currently increase the risk of bacterial resistance, toxicity, and added expense. Three-dimensional (3D) printing has gained a lot of attention in recent years and offers the opportunity to rapidly manufacture catheters, matched to patients through imaging and at a lower cost. Fused deposition modelling (FDM) in particular allows thermoplastic polymers to be printed into the desired devices from a model made using computer aided design (CAD). Limitations to FDM include the small range of thermoplastic polymers that are compatible with this form of printing and the high degradation temperature required for drugs to be extruded with the polymer. Hot-melt extrusion (HME) allows the potential for antimicrobial drugs to be added to the polymer to create catheters with antimicrobial activity, therefore being able to overcome the issue of increased rates of infection. This review will cover the area of dialysis and catheter-related infections, current manufacturing processes of catheters and methods to prevent infection, limitations of current processes of catheter manufacture, future directions into the manufacture of catheters, and how drugs can be incorporated into the polymers to help prevent infection.

Medical-Grade PCL Based Polyurethane System for FDM 3D Printing-Characterization and Fabrication

The widespread use of three-dimensional (3D) printing technologies in medicine has contributed to the increased demand for 3D printing materials. In addition, new printing materials that are appearing in the industry do not provide a detailed material characterization. In this paper, we present the synthesis and characterization of polycaprolactone (PCL) based medical-grade thermoplastic polyurethanes, which are suitable for forming in a filament that is dedicated to Fused Deposition Modeling 3D (FDM 3D)printers. For this purpose, we synthesized polyurethane that is based on PCL and 1,6-hexamethylene diisocyanate (HDI) with a different isocyanate index NCO:OH (0.9:1, 1.1:1). Particular characteristics of synthesized materials included, structural properties (FTIR, Raman), thermal (differential scanning calorimetry (DSC), thermogravimetric analysis (TGA)), mechanical and surfaces (contact angle) properties. Moreover, pre-biological tests in vitro and degradation studies were also performed. On the basis of the conducted tests, a material with more desirable properties S-TPU(PCL)0.9 was selected and the optimization of filament forming via melt-extrusion process was described. The initial biological test showed the biocompatibility of synthesized S-TPU(PCL)0.9 with respect to C2C12 cells. It was noticed that the process of thermoplastic polyurethanes (TPU) filaments forming by extrusion was significantly influenced by the appropriate ratio between the temperature profile, rotation speed, and dosage ratio.