Jia An

3D printing of smart materials: A review on recent progresses in 4D printing

ABSTRACT Additive manufacturing (AM), commonly known as three-dimensional (3D) printing or rapid prototyping, has been introduced since the late 1980s. Although a considerable amount of progress has been made in this field, there is still a lot of research work to be done in order to overcome the various challenges remained. Recently, one of the actively researched areas lies in the additive manufacturing of smart materials and structures. Smart materials are those materials that have the ability to change their shape or properties under the influence of external stimuli. With the introduction of smart materials, the AM-fabricated components are able to alter their shape or properties over time (the 4th dimension) as a response to the applied external stimuli. Hence, this gives rise to a new term called ‘4D printing’ to include the structural reconfiguration over time. In this paper, recent major progresses in 4D printing are reviewed, including 3D printing of enhanced smart nanocomposites, shape memory alloys, shape memory polymers, actuators for soft robotics, self-evolving structures, anti-counterfeiting system, active origami and controlled sequential folding, and some results from our ongoing research. In addition, some research activities on 4D bio-printing are included, followed by discussions on the challenges, applications, research directions and future trends of 4D printing.

Design and 3D Printing of Scaffolds and Tissues

ABSTRACT A growing number of three-dimensional (3D)-printing processes have been applied to tissue engineering. This paper presents a state-of-the-art study of 3D-printing technologies for tissue-engineering applications, with particular focus on the development of a computer-aided scaffold design system; the direct 3D printing of functionally graded scaffolds; the modeling of selective laser sintering (SLS) and fused deposition modeling (FDM) processes; the indirect additive manufacturing of scaffolds, with both micro and macro features; the development of a bioreactor; and 3D/4D bioprinting. Technological limitations will be discussed so as to highlight the possibility of future improvements for new 3D-printing methodologies for tissue engineering.

Clothing polymer fibers with well-aligned and high-aspect ratio carbon nanotubes

It is believed that the crucial step towards preparation of electrical conductive polymer-carbon nanotube (CNT) composites is dispersing CNTs with a high length-to-diameter aspect ratio in a well-aligned manner. However, this process is extremely challenging when dealing with long and entangled CNTs. Here in this study, a new approach is demonstrated to fabricate conductive polymer-CNT composite fibers without involving any dispersion process. Well-aligned CNT films were firstly drawn from CNT arrays, and then directly coated on polycaprolactone fibers to form polymer-CNT composite fibers. The conductivity of these composite fibers can be as high as 285 S m(-1) with only 2.5 wt% CNT loading, and reach 1549 S m(-1) when CNT loading is 13.4 wt%. As-prepared composite fibers also exhibit 82% retention of conductivity at a strain of 7%, and have improved mechanical properties.

A Mathematical Model on the Resolution of Extrusion Bioprinting for the Development of New Bioinks

Pneumatic extrusion-based bioprinting is a recent and interesting technology that is very useful for biomedical applications. However, many process parameters in the bioprinter need to be fully understood in order to print at an adequate resolution. In this paper, a simple yet accurate mathematical model to predict the printed width of a continuous hydrogel line is proposed, in which the resolution is expressed as a function of nozzle size, pressure, and printing speed. A thermo-responsive hydrogel, pluronic F127, is used to validate the model predictions. This model could provide a platform for future correlation studies on pneumatic extrusion-based bioprinting as well as for developing new bioink formulations.

A novel 3D printing method for cell alignment and differentiation

The application of bioprinting allows precision deposition of biological materials for bioengineering applications. Here we propose a 2 stage methodology for bioprinting using a back pressure-driven, automated robotic dispensing system. This apparatus can prepare topographic guidance features for cell orientation and then bioprint cells directly onto them. Topographic guidance features generate cues that influence adhered cell morphology and phenotype. The robotic dispensing system was modified to include a sharpened stylus that etched on a polystyrene surface. The same computer-aided design (CAD) software was used for both precision control of etching and bioink deposition. Various etched groove patterns such as linear, concentric circles, and sinusoidal wave patterns were possible. Fibroblasts and mesenchymal stem cells (MSC) were able to sense the grooves, as shown by their elongation and orientation in the direction of the features. The orientated MSCs displayed indications of lineage commitment as detected by fluorescence-activated cell sorting (FACS) analysis. A 2% gelatin bioink was then used to dispense cells onto the etched features using identical, programmed co-ordinates. The bioink allows the cells to contact sense the pattern while containing their deposition within the printed pattern.The application of bioprinting allows the precision deposition of biological material for bioengineering applications. Here we propose a 2 stage methodology for bioprinting using a back pressure driven automated robotic dispensing system. This apparatus can prepare topographic guidance features for cell orientation and then bioprint cells directly to them. Topographic guidance features generate cues that influence adhered cell morphology and phenotype. The robotic dispensing system was modified to include a sharpened stylus that etched a polystyrene surface. The same CAD software was used for both precision control of etching and bioink deposition. Various etched groove patterns were possible, such as linear, concentric circles and sinusoidal wave patterns. Fibroblasts and mesenchymal stem cells (MSC) could sense the grooves, elongating and orientating themselves in the direction of the features, with the MSCs displaying indications of lineage commitment. A 2% gelatin bioink was then used to dispense cells onto the etched features using identical programmed co-ordinates. The bioink allows the cells to contact sense the pattern while containing their deposition within the printed pattern.

Hierarchically self-morphing structure through 4D printing

ABSTRACT Hierarchical self-morphing refers to the concurrent global and local changes in shape or structure. Previous research works have demonstrated 3D printed self-morphing structures and the sequential folding/unfolding behaviours. However, the shape change events occurred mainly at the global level in a water environment either through absorbing moisture or through heating. Concurrent global and local shape changes in an ambient environment have not been reported. In this paper, we report a hierarchically blooming flower that blossoms in an ambient environment. Our design considers the strain limit through understanding the effect of thickness on the local strain to avoid fracture and the appropriate allocation of multiple materials to achieve predefined global and local shape changes. This design approach of hierarchical 4D printing may be useful for a variety of applications that involve controlled self-morphing structures with complex geometries.

Characterization, mechanical behavior and in vitro evaluation of a melt-drawn scaffold for esophageal tissue engineering.

Tubular esophageal scaffolds with fiber diameter ranging from 13.9±1.7μm to 65.7±6.2μm were fabricated from the highly elastic poly(l-lactide-co-ε-caprolactone) (PLC) via a melt-drawing method. The morphology, crystallinity, thermal and mechanical properties of the PLC fibers were investigated. They were highly aligned and have a uniform diameter. PLC is found to be semicrystalline consisting of α- and β- lactide (LA) crystals. The crystallinity increases up to 16.8% with increasing melt-drawing speeds due to strain-induced crystallization. Modulus and strength increases while ductility decreases with an increase in crystallinity of the PLC samples. Moisture will not degrade the overall tensile properties but affect its tangent modulus at the low strain. L929 cells are able to attach and proliferate on the scaffolds very well. The cells seeded on the scaffolds show normal morphology with >90% cell viability after 6 days of culture. These results demonstrate that the PLC fibrous scaffold has good potential for use in esophageal tissue engineering application.

Two-Way 4D Printing: A Review on the Reversibility of 3D-Printed Shape Memory Materials

Abstract The rapid development of additive manufacturing and advances in shape memory materials have fueled the progress of four-dimensional (4D) printing. With the right external stimulus, the need for human interaction, sensors, and batteries will be eliminated, and by using additive manufacturing, more complex devices and parts can be produced. With the current understanding of shape memory mechanisms and with improved design for additive manufacturing, reversibility in 4D printing has recently been proven to be feasible. Conventional one-way 4D printing requires human interaction in the programming (or shape-setting) phase, but reversible 4D printing, or two-way 4D printing, will fully eliminate the need for human interference, as the programming stage is replaced with another stimulus. This allows reversible 4D printed parts to be fully dependent on external stimuli; parts can also be potentially reused after every recovery, or even used in continuous cycles—an aspect that carries industrial appeal. This paper presents a review on the mechanisms of shape memory materials that have led to 4D printing, current findings regarding 4D printing in alloys and polymers, and their respective limitations. The reversibility of shape memory materials and their feasibility to be fabricated using three-dimensional (3D) printing are summarized and critically analyzed. For reversible 4D printing, the methods of 3D printing, mechanisms used for actuation, and strategies to achieve reversibility are also highlighted. Finally, prospective future research directions in reversible 4D printing are suggested.

Smooth Muscle Cell Alignment and Phenotype Control by Melt Spun Polycaprolactone Fibers for Seeding of Tissue Engineered Blood Vessels

A method has been developed to induce and retain a contractile phenotype for vascular smooth muscle cells, as the first step towards the development of a biomimetic blood vessel construct with minimal compliance mismatch. Melt spun PCL fibers were deposited on a mandrel to form aligned fibers of 10 μm in diameter. The fibers were bonded into aligned arrangement through dip coating in chitosan solution. This formed a surface of parallel grooves, 10 μm deep by 10 μm across, presenting a surface layer of chitosan to promote cell surface interactions. The aligned fiber surface was used to culture cells present in the vascular wall, in particular fibroblasts and smooth muscle cells. This topography induced “surface guidance” over the orientation of the cells, which adopted an elongated spindle-like morphology, whereas cells on the unpatterned control surface did not show such orientation, assuming more rhomboid shapes. The preservation of VSMC contractile phenotype on the aligned scaffold was demonstrated by the retention of α-SMA expression after several days of culture. The effect was assessed on a prototype vascular graft prosthesis fabricated from polylactide caprolactone; VSMCs aligned longitudinally along a fiberless tube, whereas, for the aligned fiber coated tubes, the VSMCs aligned in the required circumferential orientation.

1 – Introduction to rapid prototyping of biomaterials

Abstract: Rapid prototyping (RP) or additive manufacturing (AM) is a group of technologies that create three dimensional objects additively in a layer-by-layer manner. This chapter first discusses the definition of RP. It goes on to describe the basic process, the classification of RP and typical RP systems. Finally, the chapter discusses how RP can be explored for processing biomaterials and suggests possible research directions. It is the intention of the authors that this chapter will give readers a general view on rapid prototyping of biomaterials.