Jürgen Stampfl

Photopolymers with tunable mechanical properties processed by laser-based high-resolution stereolithography

Stereolithography (SLA) is a widely used technique for the fabrication of prototypes and small series products. The main advantage of SLA and related solid freeform fabrication (SFF) techniques is their capability to fabricate parts with complex shapes with high resolution. Although the spectrum of available materials has been widened in recent years, there is still a lack of materials which can be processed with SLA on a routine basis. In this work, a micro-SLA (?SLA) system is presented which can shape a number of different photopolymers with resolutions down to 5 ?m in the xy-plane and 10 ?m in the z-direction. The system is capable of processing various specifically tailored photopolymers which are based on acrylate chemistry. The materials processed for this work range from hybrid sol?gel materials (ORMOCER) to photo-crosslinked elastomers and hydrogels. The elastic moduli of these materials can be tuned over several orders of magnitude and range from 0.1 MPa to 8000 MPa. The reactivity of these monomers is sufficient for achieving writing speeds up to 500 mm s?1 which is comparable to commercial SLA resins. Various test structures are presented which show the suitability of the process for fabricating parts required for applications in micro-mechanical systems as well as for applications in biomedical engineering. Using the presented system, internal channels with a diameter of 50 ?m and a length of 1500 ?m could be fabricated. It was also possible to manufacture a micro-mechanical system consisting of a fixed axe and a free spinning turbine wheel.

Polymers for 3D Printing and Customized Additive Manufacturing

Additive manufacturing (AM) alias 3D printing translates computer-aided design (CAD) virtual 3D models into physical objects. By digital slicing of CAD, 3D scan, or tomography data, AM builds objects layer by layer without the need for molds or machining. AM enables decentralized fabrication of customized objects on demand by exploiting digital information storage and retrieval via the Internet. The ongoing transition from rapid prototyping to rapid manufacturing prompts new challenges for mechanical engineers and materials scientists alike. Because polymers are by far the most utilized class of materials for AM, this Review focuses on polymer processing and the development of polymers and advanced polymer systems specifically for AM. AM techniques covered include vat photopolymerization (stereolithography), powder bed fusion (SLS), material and binder jetting (inkjet and aerosol 3D printing), sheet lamination (LOM), extrusion (FDM, 3D dispensing, 3D fiber deposition, and 3D plotting), and 3D bioprinting. The range of polymers used in AM encompasses thermoplastics, thermosets, elastomers, hydrogels, functional polymers, polymer blends, composites, and biological systems. Aspects of polymer design, additives, and processing parameters as they relate to enhancing build speed and improving accuracy, functionality, surface finish, stability, mechanical properties, and porosity are addressed. Selected applications demonstrate how polymer-based AM is being exploited in lightweight engineering, architecture, food processing, optics, energy technology, dentistry, drug delivery, and personalized medicine. Unparalleled by metals and ceramics, polymer-based AM plays a key role in the emerging AM of advanced multifunctional and multimaterial systems including living biological systems as well as life-like synthetic systems.

Engineering 3D cell-culture matrices: multiphoton processing technologies for biological and tissue engineering applications

Cells respond to topographical, mechanical and biochemical characteristics of the surrounding environment. Capability to reconstruct these factors individually, and also acting in accord, would facilitate systematic investigations of a multitude of related biological and tissue engineering questions. The subject of the present review is a group of technologies allowing realization of customized cell-culture matrices. These methods utilize photochemistry induced by multiphoton absorption and are carried out using essentially identical equipment. Fabrication of 2D microstructured substrates, complex 3D scaffolds, containing actively induced topographies, and immobilization of biomolecules in a spatially defined manner was demonstrated with these techniques. The reviewed reports indicate that multiphoton processing is a promising technology platform for the development of standard biomimetic microenvironments for 3D cell culture.

Laser Photofabrication of Cell-Containing Hydrogel Constructs

The two-photon polymerization (2PP) of photosensitive gelatin in the presence of living cells is reported. The 2PP technique is based on the localized cross-linking of photopolymers induced by femtosecond laser pulses. The availability of water-soluble photoinitiators (PI) suitable for 2PP is crucial for applying this method to cell-containing materials. Novel PIs developed by our group allow 2PP of formulations with up to 80% cell culture medium. The cytocompatibility of these PIs was evaluated by an MTT assay. The results of cell encapsulation by 2PP show the occurrence of cell damage within the laser-exposed regions. However, some cells located in the immediate vicinity and even within the 2PP-produced structures remain viable and can further proliferate. The control experiments demonstrate that the laser radiation itself does not damage the cells at the parameters used for 2PP. On the basis of these findings and the reports by other groups, we conclude that such localized cell damage is of a chemical origin and can be attributed to reactive species generated during 2PP. The viable cells trapped within the 2PP structures but not exposed to laser radiation continued to proliferate. The live/dead staining after 3 weeks revealed viable cells occupying most of the space available within the 3D hydrogel constructs. While some of the questions raised by this study remain open, the presented results indicate the general practicability of 2PP for 3D processing of cell-containing materials. The potential applications of this highly versatile approach span from precise engineering of 3D tissue models to the fabrication of cellular microarrays.

Photo-sensitive hydrogels for three-dimensional laser microfabrication in the presence of whole organisms

Abstract. Hydrogels are polymeric materials with water contents similar to that of soft tissues. Due to their biomimetic properties, they have been extensively used in various biomedical applications including cell encapsulation for tissue engineering. The utilization of photopolymers provides a possibility for the temporal and spatial controlling of hydrogel cross-links. We produced three-dimensional (3-D) hydrogel scaffolds by means of the two-photon polymerization (2PP) technique. Using a highly efficient water-soluble initiator, photopolymers with up to 80 wt.% water were processed with high precision and reproducibility at a writing speed of 10  mm/s. The biocompatibility of the applied materials was verified using Caenorhabditis elegans as living test organisms. Furthermore, these living organisms were successfully embedded within a 200×200×35 μm3 hydrogel scaffold. As most biologic tissues exhibit a window of transparency at the wavelength of the applied femtosecond laser, it is suggested that 2PP is promising for an in situ approach. Our results demonstrate the feasibility of and potential for bio-fabricating 3-D tissue constructs in the micrometre-range via near-infrared lasers in direct contact with a living organism.

Initiation efficiency and cytotoxicity of novel water-soluble two-photon photoinitiators for direct 3D microfabrication of hydrogels

The lack of efficient water-soluble two-photon absorption (TPA) photoinitiators has been a critical obstruction for three dimensional hydrogel microfabrications with high water load by two-photon induced polymerization (TPIP). In this paper, a series of cyclic benzylidene ketone-based two-photon initiators, containing carboxylic acid sodium salts to improve water solubility, were synthesized via classical aldol condensation reactions. The cytotoxicity of cyclopentanone-based photoinitiators is as low as that of the well-known biocompatible photoinitiator Irgacure 2959 as assessed in the dark with MG63 cell line. In z-scan measurement, the TPA cross sections of the investigated initiators are only moderate in water, while the TPA values for hydrophobic analogues measured in chloroform were much higher. All novel initiators exhibited broad processing windows in TPIP tests using hydrophilic photopolymers with up to 50 wt% of water. Impressively, microfabrication of hydrogels with excellent precision was possible at a writing speed as high as 100 mm s−1.

Fabrication and moulding of cellular materials by rapid prototyping

Many biological materials (e.g. wood, cork, bone, etc) are based on cellular designs, since cellular architectures offer the possibility to optimise the properties (stiffness, density, strength, etc) of a structure according to the environmental conditions the structure is exposed to. By using rapid prototyping, it is possible to fabricate cellular materials on a similar size scale as in natural material-structures. By using appropriate moulding techniques, these structures can be fabricated out of a wide variety of materials (polymers, ceramics, composites). In this work, several RP techniques are investigated regarding their suitability for the fabrication of cellular solids. The main focus is on using direct light projection (stereolithography) in combination with gelcasting as moulding technique. Besides using commercial light-sensitive resins, a class of newly developed water-soluble resins has been evaluated regarding its usability as sacrificial mould material.

Rapid prototyping and manufacturing by gelcasting of metallic and ceramic slurries

In this work an approach for rapid prototyping and manufacturing of metallic as well as ceramic parts is presented. By using Mold Shape Deposition Manufacturing (MoldSDM), a wax mold is fabricated which is filled with a slurry containing the final part material in powder form. The wax mold is manufactured by first decomposing the desired part geometry into machinable compacts. In a next step the mold is built up in a series of layers by machining either the wax or a sacrificial support material. The surface quality of the final mold is only limited by the abilities of the CNC machine. After casting a ceramic or metallic slurry, the wax mold is removed and the obtained green part debinded and sintered. In this work the mechanical and microstructural properties of the parts obtained by this method are presented. The materials which have been investigated are silicon nitride and stainless steels. Due to the high mold quality the process is suitable for a variety of applications in rapid prototyping and manufacturing where parts made of engineering materials are required.

In vitro determination of biomechanical properties of human articular cartilage in osteoarthritis using multi-parametric MRI

The objective of this study was to evaluate the correlations between MR parameters and the biomechanical properties of naturally degenerated human articular cartilage. Human cartilage explants from the femoral condyles of patients who underwent total knee replacement were evaluated on a micro-imaging system at 3T. To quantify glycosaminoglycan (GAG) content, delayed gadolinium-enhanced MRI of the cartilage (dGEMRIC) was used. T(2) maps were created by using multi-echo, multi-slice spin echo sequences with six echoes: 15, 30, 45, 60, 75, and 90 ms. Data for apparent diffusion constant (ADC) maps were obtained from pulsed gradient spin echo (PGSE) sequences with five b-values: 10.472, 220.0, 627.0, 452.8, 724.5, and 957.7. MR parameters were correlated with mechanical parameters (instantaneous (I) and equilibrium (Eq) modulus and relaxation time (tau)), and the OA stage of each cartilage specimen was determined by histological evaluation of hematoxylin-eosin stained slices. For some parameters, a high correlation was found: the correlation of T(1Gd) vs Eq (r=0.8095), T(1Gd) vs I/Eq (r=-0.8441) and T(1Gd) vs tau (r=0.8469). The correlation of T(2) and ADC with selected biomechanical parameters was not statistically significant. In conclusion, GAG content measured by dGEMRIC is highly related to the selected biomechanical properties of naturally degenerated articular cartilage. In contrast, T(2) and ADC were unable to estimate these properties. The results of the study imply that some MR parameters can non-invasively predict the biomechanical properties of degenerated articular cartilage.

Evaluation of Biocompatible Photopolymers I: Photoreactivity and Mechanical Properties of Reactive Diluents

Important characteristics of bone replacement materials are to support the attachment, growth, and differentiation of osteogenic cells. A second important characteristic of the material is that it can be photopolymerized, which allows the material to be applied to rapid prototyping that enables us to fabricate scaffolds in nearly any shape and structure. In these investigations, reactivity and biocompatibility of different types of commercially available acrylates and photoinitiators were determined. Cell viability was related to the functional groups in the monomers present, e.g., oligoethyleneglycol, urethane‐, hydroxy‐ or carboxy groups. It was found that polymers obtained from acrylates with urethane units, most dialkylacrylamide and especially trimethylolpropane triacrylate gave outstanding biocompatibility. Mechanical testing proved to have significantly better performance (stiffness, strength) than many known thermoplastic biopolymers.