A Review of Multi-Material 3D Printing of Functional Materials via Vat Photopolymerization

Multi-material Gradient Printing Using Meniscus-enabled Projection Stereolithography (MAPS)

Light-based additive manufacturing methods have been widely used to print high-resolution 3D structures for applications in tissue engineering, soft robotics, photonics, and microfluidics, among others. Despite this progress, multi-material printing with these methods remains challenging due to constraints associated with hardware modifications, control systems, cross-contamination, waste, and resin properties. Here, we report a new printing platform coined Meniscus-enabled Projection Stereolithography (MAPS), a vat-free method that relies on generating and maintaining a resin meniscus between a crosslinked structure and bottom window to print lateral, vertical, discrete, or gradient multi-material 3D structures with no waste and user-defined mixing between layers. We show that MAPS is compatible with a wide range of resins and can print complex multi-material 3D structures without requiring specialized hardware, software, or complex washing protocols. MAPS's ability to print structures with microscale variations in mechanical stiffness, opacity, surface energy, cell densities, and magnetic properties provides a generic method to make advanced materials for a broad range of applications.

Filament Type Recognition for Additive Manufacturing Using a Spectroscopy Sensor and Machine Learning

This study presents a novel approach for filament recognition in fused filament fabrication (FFF) processes using a multi-spectral spectroscopy sensor module combined with machine learning techniques. The sensor module measures 18 wavelengths spanning the visible to near-infrared spectra, with a custom-designed shroud to ensure systematic data collection. Filament samples include polylactic acid (PLA), thermoplastic polyurethane (TPU), thermoplastic copolyester (TPC), carbon fibre, acrylonitrile butadiene styrene (ABS), and ABS blended with Carbon fibre. Data are collected using the Triad Spectroscopy module AS7265x (composed of AS72651, AS72652, AS72653 sensor units) positioned at three measurement distances (12 mm, 16 mm, 20 mm) to evaluate recognition performance under varying configurations. Machine learning models, including k-Nearest Neighbors (kNN), Logistic Regression, Support Vector Machine (SVM), and Multi-Layer Perceptron (MLP), are employed with hyperparameter tuning applied to optimise classification accuracy. Results show that the data collected on the AS72651 sensor, paired with the SVM model, achieves the highest accuracy of 98.95% at a 20 mm measurement distance. This work introduces a compact, high-accuracy filament recognition module that can enhance the autonomy of multi-material 3D printing by dynamically identifying and switching between different filaments, optimising printing parameters for each material, and expanding the versatility of additive manufacturing applications.

Three-Dimensional-Printed Photopolymer Resin Materials: A Narrative Review on Their Production Techniques and Applications in Dentistry

Additive manufacturing (3D printing) has transformed dentistry by providing solutions with high precision and accuracy achieved through digital workflows, which facilitate the creation of intricate and personalized structures. Additionally, 3D printing promotes cost efficiency by reducing material waste and errors while enabling on-demand production, minimizing the need for extensive inventories. Recent advancements in 3D-printed resin materials have enhanced their clinical applications by improving mechanical strength, biocompatibility, esthetics, and durability. These innovations have facilitated the fabrication of complex and patient-specific structures, such as dental prostheses, surgical guides, and orthodontic appliances, while significantly reducing production time and material waste. Ongoing research and innovation are expected to strengthen resin properties, including strength, translucency, and durability, broadening their clinical applications. The ongoing evolution of 3D printing technology is poised to play a critical role in driving personalized treatments, streamlining clinical workflows, and shaping the future of dental care. This narrative review comprehensively examines the production techniques and clinical applications of 3D-printed photopolymer resins across various dental specialties, including prosthodontics, orthodontics, pediatric dentistry, maxillofacial surgery, periodontology, endodontics, and conservative dentistry. Additionally, the review provides insight into the transformative impact of these technologies on patient care, highlights existing challenges, and suggests future directions for advancing resin properties and their integration into routine dental practice.

Engineering considerations in the design of tissue specific bioink for 3D bioprinting applications

Over eight million surgical procedures are conducted annually in the United Stats to address organ failure or tissue losses. In response to this pressing need, recent medical advancements have significantly improved patient outcomes, primarily through innovative reconstructive surgeries utilizing tissue grafting techniques. Despite tremendous efforts, repairing damaged tissues remains a major clinical challenge for bioengineers and clinicians. 3D bioprinting is an additive manufacturing technique that holds significant promise for creating intricately detailed constructs of tissues, thereby bridging the gap between engineered and actual tissue constructs. In contrast to non-biological printing, 3D bioprinting introduces added intricacies, including considerations for material selection, cell types, growth, and differentiation factors. However, technical challenges arise, particularly concerning the delicate nature of living cells in bioink for tissue construction and limited knowledge about the cell fate processes in such a complex biomechanical environment. A bioink must have appropriate viscoelastic and rheological properties to mimic the native tissue microenvironment and attain desired biomechanical properties. Hence, the properties of bioink play a vital role in the success of 3D bioprinted substitutes. This review comprehensively delves into the scientific aspects of tissue-centric or tissue-specific bioinks and sheds light on the current challenges of the translation of bioinks and bioprinting.

Advancing Multi-Ion Sensing with Poly-Octylthiophene: 3D-Printed Milker-Implantable Microfluidic Device

On-site rapid multi-ion sensing accelerates early identification of environmental pollution, water quality, and disease biomarkers in both livestock and humans. This study introduces a pocket-sized 3D-printed sensor, manufactured using additive manufacturing, specifically designed for detecting iron (Fe2+), nitrate (NO3 -), calcium (Ca2+), and phosphate (HPO4 2-). A unique feature of this device is its utilization of a universal ion-to-electron transducing layer made from highly redox-active poly-octylthiophene (POT), enabling an all-solid-state electrode tailored to each ion of interest. Manufactured with an extrusion-based 3D printer, the device features a periodic pattern of lateral layers (width = 80 µm), including surface wrinkles. The superhydrophobic nature of the POT prevents the accumulation of nonspecific ions at the interface between the gold and POT layers, ensuring exceptional sensor selectivity. Lithography-free, 3D-printed sensors achieve sensitivity down to 1 ppm of target ions in under a minute due to their 3D-wrinkled surface geometry. Integrated seamlessly with a microfluidic system for sample temperature stabilization, the printed sensor resides within a robust, pocket-sized 3D-printed device. This innovation integrates with milking parlors for real-time calcium detection, addressing diagnostic challenges in on-site livestock health monitoring, and has the capability to monitor water quality, soil nutrients, and human diseases.

In-situ synthesis and integration of gold nanoparticles into 3D printed optical fiber probes

This work uses the polymeric reduction method to explore the in-situ synthesis of gold nanoparticles (AuNPs) within 3D-printed optical fiber probes (OFPs). Digital light processing (DLP) 3D printing is employed to fabricate the OFPs using a resin consisting of hydroxyethyl methacrylate (HEMA) and polyethylene glycol diacrylate (PEGDA). After printing, OFPs were immersed in a boiling gold precursor solution to facilitate the synthesis of AuNPs inside the polymer matrix. We produced single material (HEMA/PEGDA) and multimaterial (HEMA/PEGDA + Dentaclear) OFPs loaded with AuNPs at different concentrations. Scanning electron microscopy analysis confirmed the effective distribution and dispersion of AuNPs within the polymer matrix. The optical properties, including reflection and transmission spectra, are comprehensively measured using customized setups. The localized surface plasmon resonance of the embedded AuNPs created a distinct dip in the 500-600 nm wavelength range. Higher AuNP concentrations and longer dipping times enhanced light absorption, reducing reflection and transmission intensities. Multimaterial OFPs also exhibited tunable wavelength filtering capabilities based on the AuNP concentration. The AuNP-loaded OFPs demonstrated stable optical performance across varying temperatures and pH environments, highlighting their potential for diverse applications.

Advances in materials and technologies for digital light processing 3D printing

Digital light processing (DLP) is a projection-based vat photopolymerization 3D printing technique that attracts increasing attention due to its high resolution and accuracy. The projection-based layer-by-layer deposition in DLP uses precise light control to cure photopolymer resin quickly, providing a smooth surface finish due to the uniform layer curing process. Additionally, the extensive material selection in DLP 3D printing, notably including existing photopolymerizable materials, presents a significant advantage compared with other 3D printing techniques with limited material choices. Studies in DLP can be categorized into two main domains: material-level and system-level innovation. Regarding material-level innovations, the development of photocurable resins with tailored rheological, photocuring, mechanical, and functional properties is crucial for expanding the application prospects of DLP technology. In this review, we comprehensively review the state-of-the-art advancements in DLP 3D printing, focusing on material innovations centered on functional materials, particularly various smart materials for 4D printing, in addition to piezoelectric ceramics and their composites with their applications in DLP. Additionally, we discuss the development of recyclable DLP resins to promote sustainable manufacturing practices. The state-of-the-art system-level innovations are also delineated, including recent progress in multi-materials DLP, grayscale DLP, AI-assisted DLP, and other related developments. We also highlight the current challenges and propose potential directions for future development. Exciting areas such as the creation of photocurable materials with stimuli-responsive functionality, ceramic DLP, recyclable DLP, and AI-enhanced DLP are still in their nascent stages. By exploring concepts like AI-assisted DLP recycling technology, the integration of these aspects can unlock significant opportunities for applications driven by DLP technology. Through this review, we aim to stimulate further interest and encourage active collaborations in advancing DLP resin materials and systems, fostering innovations in this dynamic field.

Generation of Tailored Multi-Material Microstructures Through One-Step Direct Laser Writing

Direct laser writing has gained remarkable popularity by offering architectural control of 3D objects at submicron scales. However, it faces limitations when the fabrication of microstructures comprising multiple materials is desired. The generation processes of multi-material microstructures are often very complex, requiring meticulous alignment, as well as a series of step-and-repeat writing and development of the materials. Here, a novel material system based on multilayers of chemically tailored polymers containing anthraquinone crosslinker units is demonstrated. Upon two-photon excitation, the crosslinkers only require nearby aliphatic C,H units as reaction partners to form a crosslinked network. The desired structure can be written into a solid multi-layered material system, wherein the properties of each material can be designed at the molecular level. In this way, C,H insertion crosslinking (CHic) of the polymers within each layer, along with simultaneous reaction at their interfaces, is performed, leading to the one-step fabrication of multi-material microstructures. A multi-material 3D scaffold with a sixfold symmetry is produced to precisely control the adhesion of cells both concerning surface chemistry and topology. The demonstrated material system shows great promise for the fabrication of 3D microstructures with high precision, intricate geometries and customized functionalities.

Engineered Shape-Morphing Transitions in Hydrogels Through Suspension Bath Printing of Temperature-Responsive Granular Hydrogel Inks

4D printing of hydrogels is an emerging technology used to fabricate shape-morphing soft materials that are responsive to external stimuli for use in soft robotics and biomedical applications. Soft materials are technically challenging to process with current 4D printing methods, which limits the design and actuation potential of printed structures. Here, a simple multi-material 4D printing technique is developed that combines dynamic temperature-responsive granular hydrogel inks based on hyaluronic acid, whose actuation is modulated via poly(N-isopropylacrylamide) crosslinker design, with granular suspension bath printing that provides structural support during and after the printing process. Granular hydrogels are easily extruded upon jamming due to their shear-thinning properties and their porous structure enables rapid actuation kinetics (i.e., seconds). Granular suspension baths support responsive ink deposition into complex patterns due to shear-yielding to fabricate multi-material objects that can be post-crosslinked to obtain anisotropic shape transformations. Dynamic actuation is explored by varying printing patterns and bath shapes, achieving complex shape transformations such as 'S'-shaped and hemisphere structures. Furthermore, stepwise actuation is programmed into multi-material structures by using microgels with varied transition temperatures. Overall, this approach offers a simple method to fabricate programmable soft actuators with rapid kinetics and precise control over shape morphing.

Simultaneous Color- and Dose-Controlled Thiol-Ene Resins for Multimodulus 3D Printing with Programmable Interfacial Gradients

Drawing inspiration from nature's own intricate designs, synthetic multimaterial structures have the potential to offer properties and functionality that exceed those of the individual components. However, several contemporary hurdles, from a lack of efficient chemistries to processing constraints, preclude the rapid and precise manufacturing of such materials. Herein, the development of a photocurable resin comprising color-selective initiators is reported, triggering disparate polymerization mechanisms between acrylate and thiol functionality. Exposure of the resin to UV light (365 nm) leads to the formation of a rigid, highly crosslinked network via a radical chain-growth mechanism, while violet light (405 nm) forms a soft, lightly crosslinked network via an anionic step-growth mechanism. The efficient photocurable resin is employed in multicolor digital light processing 3D printing to provide structures with moduli spanning over two orders of magnitude. Furthermore, local intensity (i.e., grayscale) control enables the formation of programmable stiffness gradients with ≈150× change in modulus occurring across sharp (≈200 µm) and shallow (≈9 mm) interfaces, mimetic of the human knee entheses and squid beaks, respectively. This study provides composition-processing-property relationships to inform advanced manufacturing of next-generation multimaterial objects having a myriad of applications from healthcare to education.

The influence of filler load in 3D printing resin-based composites

OBJECTIVE

To evaluate the influence of the barium glass (BG) filler in 3D printing resin-based composites for restorative structures.

METHODS

Experimental 3D printing resin-based composites were formulated with UDMA 70%wt, Bis-EMA 20%wt, and TEGDMA 10%wt. Photoinitiators TPO and DFI (2%wt) were used. BG was incorporated at 40%wt and 50%wt. 0%wt BG was used as negative control and the VarseoSmile Crownplus (Bego) was used as a commercial control. Specimens were printed using a 3D printer. Subsequently, specimens were washed and submitted to post-curing with 405 nm at 60ºC for 2 × 20 min at FormCure (FormLabs). 3D printing resin-based composites were evaluated by flexural strength, degree of conversion, softening in solvent, radiopacity, and cytotoxicity against gingival fibroblasts. Data were statistically analyzed using one-way ANOVA (α = 0.05).

RESULTS

No significant differences in flexural strength were showed between BG40% (90.5 ± 5,4 MPa), BG50% (102.0 ± 11.7 MPa) and VA (105.2 ± 11.7 MPa). Addition of 40% and 50% of BG showed no influence in the degree of conversion compared to VA (p > 0.05). All groups showed softening in solvent after immersion in ethanol (p < 0.05). All groups showed more than 1mmAl of radiopacity. BG50% showed significantly higher radiopacity (2.8 ± 0.3 mmAl) than other groups (p < 0,05). Cytotoxicity evaluation showed gingival cell viability higher than 80% for all groups.

SIGNIFICANCE

Addition of up to 50%wt of barium glass in experimental 3D printing resin-based composites showed promising results for long-term restorative structures.

Vat photopolymerization printing of functionalized hydrogels on commercial contact lenses

Contact lenses are widely used for vision correction and cosmetic purposes. Smart contact lenses offer further opportunities as functionalized non-invasive devices capable of simultaneous vision correction, real-time health monitoring and patient specific drug delivery. Herein, a low-cost vat photopolymerization technique is developed for directly 3D printing functionalized structures on commercially available contact lenses. The process enables controlled deposition of functionalized hydrogels, in customizable patterns, on the commercial contact lens surface with negligible optical losses. Multi-functional contact lenses can also be 3D printed with multiple materials deposited at different regions of the contact lens. Herein, the functionalities of colour blindness correction and real-time UV monitoring are demonstrated, by employing three suitable dyes incorporated into 2-hydroxyethyl methacrylate (HEMA) hydrogel structures printed on contact lenses. The results suggest that 3D printing can pave the way towards simple production of low-cost patient specific smart contact lenses.

Multi-Material 3D Printing of Biobased Epoxy Resins

Additive manufacturing (AM) has revolutionised the manufacturing industry, offering versatile capabilities for creating complex geometries directly from a digital design. Among the various 3D printing methods for polymers, vat photopolymerisation combines photochemistry and 3D printing. Despite the fact that single-epoxy 3D printing has been explored, the fabrication of multi-material bioderived epoxy thermosets remains unexplored. This study introduces the feasibility and potential of multi-material 3D printing by means of a dual-vat Digital Light Processing (DLP) technology, focusing on bioderived epoxy resins such as ELO (epoxidized linseed oil) and DGEVA (vanillin alcohol diglycidyl ether). By integrating different materials with different mechanical properties into one sample, this approach enhances sustainability and offers versatility for different applications. Through experimental characterisation, including mechanical and thermal analysis, the study demonstrates the ability to produce structures composed of different materials with tailored mechanical properties and shapes that change on demand. The findings underscore the promising technology of dual-vat DLP technology applied to sustainable bioderived epoxy monomers, allowing sustainable material production and complex structure fabrication.

Soluble Fluorinated Cardo Copolyimide as an Effective Additive to Photopolymerizable Compositions Based on Di(meth)acrylates: Application for Highly Thermostable Primary Protective Coating of Silica Optical Fiber

The development of photocurable compositions is in high demand for the manufacture of functional materials for electronics, optics, medicine, energy, etc. The properties of the final photo-cured material are primarily determined by the initial mixture, which needs to be tuned for each application. In this study we propose to use simple systems based on di(meth)acrylate, polyimide and photoinitiator for the preparation of new photo-curable compositions. It was established that a fluorinated cardo copolyimide (FCPI) based on 2,2-bis-(3,4-dicarboxydiphenyl)hexafluoropropane dianhydride, 9,9-bis-(4-aminophenyl)fluorene and 2,2-bis-(4-aminophenyl)hexafluoropropane (1.00:0.75:0.25 mol) has excellent solubility in di(met)acrylates. This made it possible to prepare solutions of FCPI in such monomers, to study the effect of FCPI on the kinetics of their photopolymerization in situ and the properties of the resulting polymers. According to the obtained data, the solutions of FCPI (23 wt.%) in 1,4-butanediol diacrylate (BDDA) and FCPI (15 wt.%) in tetraethylene glycol diacrylate were tested for the formation of the primary protective coatings of the silica optical fibers. It was found that the new coating of poly(BDDA-FCPI23%) can withstand prolonged annealing at 200 °C (72 h), which is comparable or superior to the known most thermally stable photo-curable coatings. The proposed approach can be applied to obtain other functional materials.

Application of 3D, 4D, 5D, and 6D bioprinting in cancer research: what does the future look like?

The application of three- and four-dimensional (3D/4D) printing in cancer research represents a significant advancement in understanding and addressing the complexities of cancer biology. 3D/4D materials provide more physiologically relevant environments compared to traditional two-dimensional models, allowing for a more accurate representation of the tumor microenvironment that enables researchers to study tumor progression, drug responses, and interactions with surrounding tissues under conditions similar to in vivo conditions. The dynamic nature of 4D materials introduces the element of time, allowing for the observation of temporal changes in cancer behavior and response to therapeutic interventions. The use of 3D/4D printing in cancer research holds great promise for advancing our understanding of the disease and improving the translation of preclinical findings to clinical applications. Accordingly, this review aims to briefly discuss 3D and 4D printing and their advantages and limitations in the field of cancer. Moreover, new techniques such as 5D/6D printing and artificial intelligence (AI) are also introduced as methods that could be used to overcome the limitations of 3D/4D printing and opened promising ways for the fast and precise diagnosis and treatment of cancer.

Multi-color dual wavelength vat photopolymerization 3D printing via spatially controlled acidity

Dual wavelength vat photopolymerization (DW-VP) has emerged as a powerful approach to create multimaterial objects. However, only a limited range of properties have been showcased. In this work, we report the 3D printing (3DP) of multi-color objects from a single resin vat using DW-VP. This was accomplished by concurrently curing resin with visible light and modulating local resin color with 365-nm ultraviolet (UV) light. The key advance was to use a photoacid generator (PAG) in combination with pH responsive dyes in the 3DP resins. The specific color is dictated by the extent of reaction, or local acidity in our case, and controlled by the light dosage and pattern of UV light applied. Multi-color object formation was implemented in two-step processes involving first 3DP to set the object structure, followed by UV exposure, as well as single processes that leveraged DW-VP to create a broad range of vibrant colors and patterns.

Direct laser writing-enabled 3D printing strategies for microfluidic applications

Over the past decade, additive manufacturing-or "three-dimensional (3D) printing"-has attracted increasing attention in the Lab on a Chip community as a pathway to achieve sophisticated system architectures that are difficult or infeasible to fabricate via conventional means. One particularly promising 3D manufacturing technology is "direct laser writing (DLW)", which leverages two-photon (or multi-photon) polymerization (2PP) phenomena to enable high geometric versatility, print speeds, and precision at length scales down to the 100 nm range. Although researchers have demonstrated the potential of using DLW for microfluidic applications ranging from organ on a chip and drug delivery to micro/nanoparticle processing and soft microrobotics, such scenarios present unique challenges for DLW. Specifically, microfluidic systems typically require macro-to-micro fluidic interfaces (e.g., inlet and outlet ports) to facilitate fluidic loading, control, and retrieval operations; however, DLW-based 3D printing relies on a micron-to-submicron-sized 2PP volume element (i.e., "voxel") that is poorly suited for manufacturing these larger-scale fluidic interfaces. In this Tutorial Review, we highlight and discuss the four most prominent strategies that researchers have developed to circumvent this trade-off and realize macro-to-micro interfaces for DLW-enabled microfluidic components and systems. In addition, we consider the possibility that-with the advent of next-generation commercial DLW printers equipped with new dynamic voxel tuning, print field, and laser power capabilities-the overall utility of DLW strategies for Lab on a Chip fields may soon expand dramatically.

A review of the recent achievements and future trends on 3D printed microfluidic devices for bioanalytical applications

3D printing has revolutionized the manufacturing process of microanalytical devices by enabling the automated production of customized objects. This technology promises to become a fundamental tool, accelerating investigations in critical areas of health, food, and environmental sciences. This microfabrication technology can be easily disseminated among users to produce further and provide analytical data to an interconnected network towards the Internet of Things, as 3D printers enable automated, reproducible, low-cost, and easy fabrication of microanalytical devices in a single step. New functional materials are being investigated for one-step fabrication of highly complex 3D printed parts using photocurable resins. However, they are not yet widely used to fabricate microfluidic devices. This is likely the critical step towards easy and automated fabrication of sophisticated, complex, and functional 3D-printed microchips. Accordingly, this review covers recent advances in the development of 3D-printed microfluidic devices for point-of-care (POC) or bioanalytical applications such as nucleic acid amplification assays, immunoassays, cell and biomarker analysis and organs-on-a-chip. Finally, we discuss the future implications of this technology and highlight the challenges in researching and developing appropriate materials and manufacturing techniques to enable the production of 3D-printed microfluidic analytical devices in a single step.

3D-Printed Smartwatch Fabricated via Vat Photopolymerization for UV and Temperature Sensing Applications

Ultraviolet (UV) exposure overdose can cause health issues such as skin burns or other skin damage. In this work, a UV and temperature sensor smartwatch is developed, utilizing a multimaterial 3D printing approach via a vat photopolymerization-digital light processing technique. Photochromic (PC) pigments with different UV sensitivities, UVA (315-400 nm) and UVB (315-280 nm), were utilized to cover a wider range of UV exposure and were mixed in transparent resin, whereas the smartwatch was printed with controlled thickness gradients. A multifunctional sensor was next fabricated by adding a thermochromic (TC) material to PC, which is capable of sensing UV and temperature change. Colorimetric measurements assisted by a smartphone-based application provided instantaneous as well as cumulative UV exposure from sunlight. The mechanical properties of the device were also measured to determine its durability. The prototype of the wearable watch was prepared by fixing the 3D-printed dial to a commercially available silicon wristband suitable for all age groups. The 3D-printed watch is water-resistant and easily removable, allowing for its utilization in multiple outdoor activities. Thus, the developed wearable UV sensor alerts the user to the extent of their UV exposure, which can help protect them against overexposure.

In Vivo Osteogenic and Angiogenic Properties of a 3D-Printed Isosorbide-Based Gyroid Scaffold Manufactured via Digital Light Processing

INTRODUCTION

Osteogenic and angiogenic properties of synthetic bone grafts play a crucial role in the restoration of bone defects. Angiogenesis is recognised for its support in bone regeneration, particularly in larger defects. The objective of this study is to evaluate the new bone formation and neovascularisation of a 3D-printed isosorbide-based novel CSMA-2 polymer in biomimetic gyroid structures.

METHODS

The gyroid scaffolds were fabricated by 3D printing CSMA-2 polymers with different hydroxyapatite (HA) filler concentrations using the digital light processing (DLP) method. A small animal subcutaneous model and a rat calvaria critical-size defect model were performed to analyse tissue compatibility, angiogenesis, and new bone formation.

RESULTS

The in vivo results showed good biocompatibility of the 3D-printed gyroid scaffolds with no visible prolonged inflammatory reaction. Blood vessels were found to infiltrate the pores from day 7 of the implantation. New bone formation was confirmed with positive MT staining and BMP-2 expression, particularly on scaffolds with 10% HA. Bone volume was significantly higher in the CSMA-2 10HA group compared to the sham control group.

DISCUSSION AND CONCLUSIONS

The results of the subcutaneous model demonstrated a favourable tissue response, including angiogenesis and fibrous tissue, indicative of the early wound healing process. The results from the critical-size defect model showcased new bone formation, as confirmed by micro-CT imaging and immunohistochemistry. The combination of CSMA-2 as the 3D printing material and the gyroid as the 3D structure was found to support essential events in bone healing, specifically angiogenesis and osteogenesis.

Fabrication of Composite Material by Directly Printing Resin on Aluminum Foam by 3D Printer

Aluminum foam has relatively low tensile and flexural strengths because it is composed of many pores with thin cell walls. One method of strengthening aluminum foam is to fabricate a composite material with a dense lightweight resin. In this study, the fabrication of composite materials by directly printing resin on an aluminum foam surface using a 3D printer was attempted. The resin was directly printed on both heated and unheated aluminum foam. It was shown that composite materials consisting of aluminum foam and resin can be fabricated by directly printing resin with a 3D printer on both heated and unheated aluminum foam. The resin was softened during the printing process in the case of directly printed resin on heated aluminum foam, allowing more resin to penetrate into the pores than in the case of directly printed resin on unheated aluminum foam. In addition, it was shown that resin can be directly printed on the aluminum foam with a high bonding strength, as a large amount of resin penetrated into the pores, resulting in an anchor effect. That is, composite materials consisting of aluminum foam and arbitrary-shaped resin with relatively high bonding strength can be fabricated when a large amount of resin is allowed to penetrate into the pore.

The microspheres/hydrogels scaffolds based on the proteins, nucleic acids, or polysaccharides composite as carriers for tissue repair: A review

There are many studies on specific macromolecules and their contributions to tissue repair. Macromolecules have supporting and protective effects in organisms and can help regrow, reshape, and promote self-repair and regeneration of damaged tissues. Macromolecules, such as proteins, nucleic acids, and polysaccharides, can be constructed into hydrogels for the preparation of slow-release drug agents, carriers for cell culture, and platforms for gene delivery. Hydrogels and microspheres are fabricated by chemical crosslinking or mixed co-deposition often used as scaffolds, drug carriers, or cell culture matrix, provide proper mechanical support and nutrient delivery, a well-conditioned environment that to promote the regeneration and repair of damaged tissues. This review provides a comprehensive overview of recent developments in the construction of macromolecules into hydrogels and microspheres based on the proteins, nucleic acids, polysaccharides and other polymer and their application in tissue repair. We then discuss the latest research trends regarding the advantages and disadvantages of these composites in repair tissue. Further, we examine the applications of microspheres/hydrogels in different tissue repairs, such as skin tissue, cartilage, tumor tissue, synovial, nerve tissue, and cardiac repair. The review closes by highlighting the challenges and prospects of microspheres/hydrogels composites.

Shape Memory Polymer Composites: 4D Printing, Smart Structures, and Applications

Shape memory polymers (SMPs) and their composites (SMPCs) are smart materials that can be stably deformed and then return to their original shape under external stimulation, thus having a memory of their shape. Three-dimensional (3D) printing is an advanced technology for fabricating products using a digital software tool. Four-dimensional (4D) printing is a new generation of additive manufacturing technology that combines shape memory materials and 3D printing technology. Currently, 4D-printed SMPs and SMPCs are gaining considerable research attention and are finding use in various fields, including biomedical science. This review introduces SMPs, SMPCs, and 4D printing technologies, highlighting several special 4D-printed structures. It summarizes the recent research progress of 4D-printed SMPs and SMPCs in various fields, with particular emphasis on biomedical applications. Additionally, it presents an overview of the challenges and development prospects of 4D-printed SMPs and SMPCs and provides a preliminary discussion and useful reference for the research and application of 4D-printed SMPs and SMPCs.

Application of 3D Bioprinting in Liver Diseases

Liver diseases are the primary reason for morbidity and mortality in the world. Owing to a shortage of organ donors and postoperative immune rejection, patients routinely suffer from liver failure. Unlike 2D cell models, animal models, and organoids, 3D bioprinting can be successfully employed to print living tissues and organs that contain blood vessels, bone, and kidney, heart, and liver tissues and so on. 3D bioprinting is mainly classified into four types: inkjet 3D bioprinting, extrusion-based 3D bioprinting, laser-assisted bioprinting (LAB), and vat photopolymerization. Bioinks for 3D bioprinting are composed of hydrogels and cells. For liver 3D bioprinting, hepatic parenchymal cells (hepatocytes) and liver nonparenchymal cells (hepatic stellate cells, hepatic sinusoidal endothelial cells, and Kupffer cells) are commonly used. Compared to conventional scaffold-based approaches, marked by limited functionality and complexity, 3D bioprinting can achieve accurate cell settlement, a high resolution, and more efficient usage of biomaterials, better mimicking the complex microstructures of native tissues. This method will make contributions to disease modeling, drug discovery, and even regenerative medicine. However, the limitations and challenges of this method cannot be ignored. Limitation include the requirement of diverse fabrication technologies, observation of drug dynamic response under perfusion culture, the resolution to reproduce complex hepatic microenvironment, and so on. Despite this, 3D bioprinting is still a promising and innovative biofabrication strategy for the creation of artificial multi-cellular tissues/organs.

Excellent Characteristics of Environmentally Friendly 3D-Printed Nasopharyngeal Swabs for Medical Sample Collection

3D-printed nasopharyngeal swabs for medical sample collection have been manufactured via additive manufacturing (AM), evaluated, and characterized in the present study. A multi-part component of nasopharyngeal swabs was proposed, in which the swab and handle were manufactured separately to reach sustainable production and environmentally friendly products. The swab was investigated using tensile, flexural, surface roughness, dimensional accuracy, and sample collection testing. The influence of printing parameters and post-curing time treatment on the mechanical properties, surface roughness, and dimensional accuracy of 3D-printed nasopharyngeal swabs were also evaluated. The result showed that 3D-printed nasopharyngeal swab shows outstanding tensile strength compared to the commercial flock nasopharyngeal swab. Moreover, the swab neck flexibility test showed that both PLA and dental non-castable 3D-printed nasopharyngeal swabs were able to bend 180°. Subsequently, the surface roughness of 3D-printed nasopharyngeal swab was identic with the commercial flock nasopharyngeal swab. The proposed 3D-printed nasopharyngeal swab design could carry an artificial mucus sample of 141.6 mg at a viscosity of 9455.4 mPa.s. The cost to fabricate a 3D-printed nasopharyngeal swab was estimated at USD0.01-0.02 per swab. 3D-printed nasopharyngeal swab shows potential as a feasible option, greener, less medical waste, and more sustainable.

Temporally Stable Supramolecular Polymeric Salts Enabling High-Performance 3D All-Aromatic Polyimide Lattices

Vat photopolymerization (VP) Additive Manufacturing (AM), in which UV light is selectively applied to cure photo-active polymers into complex geometries with micron-scale resolution, has a limited selection of aliphatic thermoset materials that exhibit relatively poor thermal performance. Ring-opening dianhydrides with acrylate-containing nucleophiles yielded diacrylate ester-dicarboxylic acids that enabled photo-active polyimide (PI) precursors, termed polysalts, upon neutralization with an aromatic diamine in solution. In situ FTIR spectroscopy coupled with a solution and photo-rheological measurements revealed a previously unknown time-dependent instability of 4,4'-oxydianiline (ODA) polysalts due to an aza-Michael addition. Replacement of the electron-donating ether-containing diamine with an electron withdrawing sulfone-containing monomer, e.g., 4,4'-diaminodiphenyl sulfone (DDS), prohibited the aza-Michael addition of the aromatic amine to the activated acrylate double bond. Novel DDS polysalt photocurable solutions are similarly analyzed and validated long-term stability, which enabled reproducible printing of polyimide organogel intermediates. Subsequent VP AM afforded 3-dimensional (3D) structures of intricate complexity and excellent surface finish, as demonstrated with scanning electron microscopy. In addition, the novel PMDA-HEA/DDS solution enabled the production of the first beam latticed architecture comprised of all-aromatic polyimide. The versatility of a polysalt platform for multi-material printing is further demonstrated by printing parts with alternating polysalt compositions.

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

Additive manufacturing (AM) has experienced exponential growth over the past two decades and now stands on the cusp of a transformative paradigm shift into the realm of multi-functional component manufacturing, known as multi-material AM (MMAM). While progress in MMAM has been more gradual compared to single-material AM, significant strides have been made in exploring the scientific and technological possibilities of this emerging field. Researchers have conducted feasibility studies and investigated various processes for multi-material deposition, encompassing polymeric, metallic, and bio-materials. To facilitate further advancements, this review paper addresses the pressing need for a consolidated document on MMAM that can serve as a comprehensive guide to the state of the art. Previous reviews have tended to focus on specific processes or materials, overlooking the overall picture of MMAM. Thus, this pioneering review endeavors to synthesize the collective knowledge and provide a holistic understanding of the multiplicity of materials and multiscale processes employed in MMAM. The review commences with an analysis of the implications of multiplicity, delving into its advantages, applications, challenges, and issues. Subsequently, it offers a detailed examination of MMAM with respect to processes, materials, capabilities, scales, and structural aspects. Seven standard AM processes and hybrid AM processes are thoroughly scrutinized in the context of their adaptation for MMAM, accompanied by specific examples, merits, and demerits. The scope of the review encompasses material combinations in polymers, composites, metals-ceramics, metal alloys, and biomaterials. Furthermore, it explores MMAM's capabilities in fabricating bi-metallic structures and functionally/compositionally graded materials, providing insights into various scale and structural aspects. The review culminates by outlining future research directions in MMAM and offering an overall outlook on the vast potential of multiplicity in this field. By presenting a comprehensive and integrated perspective, this paper aims to catalyze further breakthroughs in MMAM, thus propelling the next generation of multi-functional component manufacturing to new heights by capitalizing on the unprecedented possibilities of MMAM.

Three-Dimensional Bioprinting of Naturally Derived Hydrogels for the Production of Biomimetic Living Tissues: Benefits and Challenges

Three-dimensional bioprinting is the process of manipulating cell-laden bioinks to fabricate living structures. Three-dimensional bioprinting techniques have brought considerable innovation in biomedicine, especially in the field of tissue engineering, allowing the production of 3D organ and tissue models for in vivo transplantation purposes or for in-depth and precise in vitro analyses. Naturally derived hydrogels, especially those obtained from the decellularization of biological tissues, are promising bioinks for 3D printing purposes, as they present the best biocompatibility characteristics. Despite this, many natural hydrogels do not possess the necessary mechanical properties to allow a simple and immediate application in the 3D printing process. In this review, we focus on the bioactive and mechanical characteristics that natural hydrogels may possess to allow efficient production of organs and tissues for biomedical applications, emphasizing the reinforcement techniques to improve their biomechanical properties.

Evaluation of separating media for autopolymerizing acrylic resin fabricated on 3D-printed acrylate-based resin dental casts

STATEMENT OF PROBLEM

Limited data are available regarding the most suitable separating medium for fabricating dental acrylic resin prostheses or appliances on 3-dimensional (3D)-printed resin casts.

PURPOSE

The purpose of this in vitro study was to investigate and evaluate different separating media in terms of the ease of removal and detail reproduction of an autopolymerizing acrylic resin fabricated on acrylate-based 3D-printed resin casts.

MATERIAL AND METHODS

A cube-shaped cast was designed with a built-in truncated cone-shaped hole and a V-shaped groove at the base. Seventy-five casts were 3D-printed using acrylate-based resin and assigned to 5 groups according to the applied separating media: Siliform BEA (silicone-based), IMPRIMO 3D (alginate-based), 3D Modellisolierung (wax-based), TECHNOSIL (alginate-based), and none (control). After the application of the separating media, the truncated cone-shaped holes in the specimens were filled with autopolymerizing acrylic resin. The efficacy of the separating media was evaluated according to the ease of removal on a scale of 1 to 3 and accurate detail reproduction of the V-shaped groove on a scale of 1 to 3 under ×6 magnification. The nonparametric Kruskal-Wallis rank test was used to identify significant differences among the separating media (α=.05).

RESULTS

Significant differences were found among the groups (P<.001). Siliform BEA and 3D Modellisolierung had the best mean rank in both the ease of removal and detail reproduction scores, which were significantly different from those of the alginate-based separating media (IMPRIMO 3D and TECHNOSIL) and the control group (P<.01).

CONCLUSIONS

The dedicated silicone- and wax-based separating media for 3D-printed casts exhibited the most favorable performance in terms of ease of removal and detail reproduction.

Recent Advances on 3D-Printed Zirconia-Based Dental Materials: A Review

Zirconia-based materials are widely used in dentistry due to their biocompatibility and suitable mechanical and tribological behavior. Although commonly processed by subtractive manufacturing (SM), alternative techniques are being explored to reduce material waste, energy consumption and production time. 3D printing has received increasing interest for this purpose. This systematic review intends to gather information on the state of the art of additive manufacturing (AM) of zirconia-based materials for dental applications. As far as the authors know, this is the first time that a comparative analysis of these materials' properties has been performed. It was performed following the PRISMA guidelines and using PubMed, Scopus and Web of Science databases to select studies that met the defined criteria without restrictions on publication year. Stereolithography (SLA) and digital light processing (DLP) were the techniques most focused on in the literature and the ones that led to most promising outcomes. However, other techniques, such as robocasting (RC) and material jetting (MJ), have also led to good results. In all cases, the main concerns are centered on dimensional accuracy, resolution, and insufficient mechanical strength of the pieces. Despite the struggles inherent to the different 3D printing techniques, the commitment to adapt materials, procedures and workflows to these digital technologies is remarkable. Overall, the research on this topic can be seen as a disruptive technological progress with a wide range of application possibilities.

Rapid fabrication and screening of tailored functional 3D biomaterials: Validation in bone tissue repair - Part II

Regenerative medicine strategies place increasingly sophisticated demands on 3D biomaterials to promote tissue formation at sites where tissue would otherwise not form. Ideally, the discovery/fabrication of the 3D scaffolds needs to be high-throughput and uniform to ensure quick and in-depth analysis in order to pinpoint appropriate chemical and mechanical properties of a biomaterial. Herein we present a versatile technique to screen new potential biocompatible acrylate-based 3D scaffolds with the ultimate aim of application in tissue repair. As part of this process, we identified an acrylate-based 3D porous scaffold that promoted cell proliferation followed by accelerated tissue formation, pre-requisites for tissue repair. Scaffolds were fabricated by a facile freeze-casting and an in-situ photo-polymerization route, embracing a high-throughput synthesis, screening and characterization protocol. The current studies demonstrate the dependence of cellular growth and vascularization on the porosity and intrinsic chemical nature of the scaffolds, with tuneable 3D scaffolds generated with large, interconnected pores suitable for cellular growth applied to skeletal reparation. Our studies showed increased cell proliferation, collagen and ALP expression, while chorioallantoic membrane assays indicated biocompatibility and demonstrated the angiogenic nature of the scaffolds. VEGRF2 expression in vivo observed throughout the 3D scaffolds in the absence of growth factor supplementation demonstrates a potential for angiogenesis. This novel platform provides an innovative approach to 3D scanning of synthetic biomaterials for tissue regeneration.

A practical perspective for chromatic orthogonality for implementing in photolithography

Theoretically, it is more challenging to anticipate the conversion and selectivity of a photochemical experiment compared to thermally generated reactivity. This is due to the interaction of light with a photoreactive substrate. Photochemical reactions do not yet receive the same level of broad analytical study. Here, we close this research gap by presenting a methodology for statistically forecasting the time-dependent progression of photoreactions using widely available LEDs. This study uses NiS/ZnO in perovskite (MAPbI₃) solar cells as an additive (5 volume %). The effect of monolithic perovskite solar cells (mPSCs) on forecasting the wavelength of LEDs has been carefully investigated using various characterization methods, including X-ray diffraction (XRD) and Transmission electron microscopy (TEM). The photocatalytic activity was analyzed by measuring the voltage produced. Various factors like selectivity, stability and sensitivity were also examined. This work provides a new perspective to validate NiS/ZnO photocatalysts for predicting the wavelength of different light sources and to apply in photolithography.

Vat Photopolymerization 3D-Printing of Dynamic Thiol-Acrylate Photopolymers Using Bio-Derived Building Blocks

As an energy-efficient additive manufacturing process, vat photopolymerization 3D-printing has become a convenient technology to fabricate functional devices with high resolution and freedom in design. However, due to their permanently crosslinked network structure, photopolymers are not easily reprocessed or repaired. To improve the environmental footprint of 3D-printed objects, herein, we combine the dynamic nature of hydroxyl ester links, undergoing a catalyzed transesterification at elevated temperature, with an acrylate monomer derived from renewable resources. As a sustainable building block, we synthesized an acrylated linseed oil and mixed it with selected thiol crosslinkers. By careful selection of the transesterification catalyst, we obtained dynamic thiol-acrylate resins with a high cure rate and decent storage stability, which enabled the digital light processing (DLP) 3D-printing of objects with a structure size of 550 µm. Owing to their dynamic covalent bonds, the thiol-acrylate networks were able to relax 63% of their initial stress within 22 min at 180 °C and showed enhanced toughness after thermal annealing. We exploited the thermo-activated reflow of the dynamic networks to heal and re-shape the 3D-printed objects. The dynamic thiol-acrylate photopolymers also demonstrated promising healing, shape memory, and re-shaping properties, thus offering great potential for various industrial fields such as soft robotics and electronics.

Digital Light Processing 3D Printing of Gyroid Scaffold with Isosorbide-Based Photopolymer for Bone Tissue Engineering

As one of the most transplanted tissues of the human body, bone has varying architectures, depending on its anatomical location. Therefore, bone defects ideally require bone substitutes with a similar structure and adequate strength comparable to native bones. Light-based three-dimensional (3D) printing methods allow the fabrication of biomimetic scaffolds with high resolution and mechanical properties that exceed the result of commonly used extrusion-based printing. Digital light processing (DLP) is known for its faster and more accurate printing than other 3D printing approaches. However, the development of biocompatible resins for light-based 3D printing is not as rapid as that of bio-inks for extrusion-based printing. In this study, we developed CSMA-2, a photopolymer based on Isosorbide, a renewable sugar derivative monomer. The CSMA-2 showed suitable rheological properties for DLP printing. Gyroid scaffolds with high resolution were successfully printed. The 3D-printed scaffolds also had a compressive modulus within the range of a human cancellous bone modulus. Human adipose-derived stem cells remained viable for up to 21 days of incubation on the scaffolds. A calcium deposition from the cells was also found on the scaffolds. The stem cells expressed osteogenic markers such as RUNX2, OCN, and OPN. These results indicated that the scaffolds supported the osteogenic differentiation of the progenitor cells. In summary, CSMA-2 is a promising material for 3D printing techniques with high resolution that allow the fabrication of complex biomimetic scaffolds for bone regeneration.

New Approach for Extrusion Additive Manufacturing of Soft and Elastic Articles from Liquid-PVC-Based Consumable Materials

The article deals with the experimental development of a novel additive manufacturing (AM) process using a liquid consumable based on polyvinyl chloride plastisol. A conventional additive manufacturing system designed for deposition of melt filaments was converted to deposition of liquid material. Additive manufacturing with liquid plastisol enables the production of parts with low Shore A hardness and high ductility, surpassing the performance of the conventional filament process. The novel AM process enables the production of articles with a Shore A hardness of 5 to 60, and the mechanical properties of the additively manufactured articles are similar to those produced in the mold. This was achieved by varying the parameters of the AM process as well as the composition of the plastisol composition, including those filled with an inorganic filler. The application of different material distribution patterns also has a significant effect on the mechanical properties of the samples. A potential application of the investigated AM method was proposed and practically evaluated.