3D Printing of Bioceramic Scaffolds—Barriers to the Clinical Translation: From Promise to Reality, and Future Perspectives

In this review, we summarize the challenges of the three-dimensional (3D) printing of porous bioceramics and their translational hurdles to clinical applications. The state-of-the-art of the major 3D printing techniques (powder-based and slurry-based), their limitations and key processing parameters are discussed in detail. The significant roadblocks that prevent implementation of 3D printed bioceramics in tissue engineering strategies, and medical applications are outlined, and the future directions where new research may overcome the limitations are proposed. In recent years, there has been an increasing demand for a nanoscale control in 3D fabrication of bioceramic scaffolds via emerging techniques such as digital light processing, two-photon polymerization, or large area maskless photopolymerization. However, these techniques are still in a developmental stage and not capable of fabrication of large-sized bioceramic scaffolds; thus, there is a lack of sufficient data to evaluate their contribution. This review will also not cover polymer matrix composites reinforced with particulate bioceramics, hydrogels reinforced with particulate bioceramics, polymers coated with bioceramics and non-porous bioceramics.

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EHMP-DLP: multi-projector DLP with energy homogenization for large-size 3D printing

Rapid Prototyping Journal ◽

10.1108/rpj-04-2017-0060 ◽

2018 ◽

Vol 24 (9) ◽

pp. 1500-1510 ◽

Cited By ~ 2

Author(s):

Lifang Wu ◽

Lidong Zhao ◽

Meng Jian ◽

Yuxin Mao ◽

Miao Yu ◽

...

Keyword(s):

3D Printing ◽

Three Dimensional ◽

Digital Micromirror Device ◽

Large Area ◽

Digital Light Processing ◽

Content Type ◽

Large Size ◽

Multiple Projectors ◽

Ultraviolet Energy ◽

Practical Implications

Purpose In some three-dimensional (3D) printing application scenarios, e.g., model manufacture, it is necessary to print large-sized objects. However, it is impossible to implement large-size 3D printing using a single projector in digital light processing (DLP)-based mask projection 3D printing because of the limitations of the digital micromirror device chips. Design/methodology/approach A multi-projector DLP with energy homogenization (EHMP-DLP) scheme is proposed for large-size 3D printing. First, a large-area printing plane is established by tiling multiple projectors. Second, the projector set’s tiling pattern is obtained automatically, and the maximum printable plane is determined. Third, the energy is homogenized across the entire printable plane by adjusting gray levels of the images input into the projectors. Finally, slices are automatically segmented based on the tiling pattern of the projector set, and the gray levels of these slices are reassigned based on the images of the corresponding projectors. Findings Large-area high-intensity projection for mask projection 3D printing can be performed by tiling multiple DLP projectors. The tiled projector output energies can be homogenized by adjusting the images of the projectors. Uniform ultraviolet energy is important for high-quality printing. Practical implications A prototype device is constructed using two projectors. The printable area becomes 140 × 210 mm from the original 140 × 110 mm. Originality/value The proposed EHMP-DLP scheme enables 3D printing of large-size objects with linearly increasing printing times and high printing precision. A device was established using two projectors to practice the scheme and can easily be extended to larger sizes by using more projectors.

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3D Printing of Thermo-Sensitive Drugs

Pharmaceutics ◽

10.3390/pharmaceutics13091524 ◽

2021 ◽

Vol 13 (9) ◽

pp. 1524

Author(s):

Sadikalmahdi Abdella ◽

Souha H. Youssef ◽

Franklin Afinjuomo ◽

Yunmei Song ◽

Paris Fouladian ◽

...

Keyword(s):

3D Printing ◽

Three Dimensional ◽

Fused Deposition Modelling ◽

Future Directions ◽

Digital Light Processing ◽

Fused Deposition ◽

Printing Technique ◽

3D Printed ◽

Semi Solid ◽

Selection Of

Three-dimensional (3D) printing is among the rapidly evolving technologies with applications in many sectors. The pharmaceutical industry is no exception, and the approval of the first 3D-printed tablet (Spiratam®) marked a revolution in the field. Several studies reported the fabrication of different dosage forms using a range of 3D printing techniques. Thermosensitive drugs compose a considerable segment of available medications in the market requiring strict temperature control during processing to ensure their efficacy and safety. Heating involved in some of the 3D printing technologies raises concerns regarding the feasibility of the techniques for printing thermolabile drugs. Studies reported that semi-solid extrusion (SSE) is the commonly used printing technique to fabricate thermosensitive drugs. Digital light processing (DLP), binder jetting (BJ), and stereolithography (SLA) can also be used for the fabrication of thermosensitive drugs as they do not involve heating elements. Nonetheless, degradation of some drugs by light source used in the techniques was reported. Interestingly, fused deposition modelling (FDM) coupled with filling techniques offered protection against thermal degradation. Concepts such as selection of low melting point polymers, adjustment of printing parameters, and coupling of more than one printing technique were exploited in printing thermosensitive drugs. This systematic review presents challenges, 3DP procedures, and future directions of 3D printing of thermo-sensitive formulations.

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3D Printing in Dentistry—State of the Art

Operative Dentistry ◽

10.2341/18-229-l ◽

2020 ◽

Vol 45 (1) ◽

pp. 30-40 ◽

Cited By ~ 14

Author(s):

A Kessler ◽

R Hickel ◽

M Reymus

Keyword(s):

3D Printing ◽

Clinical Application ◽

Industrial Revolution ◽

Rapid Development ◽

Selective Laser Sintering ◽

Three Dimensional ◽

Fused Filament Fabrication ◽

Digital Light Processing ◽

Materials Used ◽

Binder Jetting

SUMMARY Three-dimensional (3D) printing is a rapidly developing technology that has gained widespread acceptance in dentistry. Compared to conventional (lost-wax technique) and subtractive computer numeric controlled methods, 3D printing offers process engineering advantages. Materials such as plastics, metals, and ceramics can be manufactured using various techniques. 3D printing was introduced over three decades ago. Today, it is experiencing rapid development due to the expiration of many patents and is often described as the key technology of the next industrial revolution. The transition to its clinical application in dentistry is highly dependent on the available materials, which must not only provide the required accuracy but also the necessary biological and physical properties. The aim of this work is to provide an up-to-date overview of the different printing techniques: stereolithography, digital light processing, photopolymer jetting, material jetting, binder jetting, selective laser sintering, selective laser melting, and fused filament fabrication. Additionally, particular attention is paid to the materials used in dentistry and their clinical application.

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Porous cage-derived nanomaterial inks for direct and internal three-dimensional printing

Nature Communications ◽

10.1038/s41467-020-18495-5 ◽

2020 ◽

Vol 11 (1) ◽

Author(s):

Tangi Aubert ◽

Jen-Yu Huang ◽

Kai Ma ◽

Tobias Hanrath ◽

Ulrich Wiesner

Keyword(s):

3D Printing ◽

Structural Control ◽

High Surface ◽

High Surface Area ◽

Three Dimensional ◽

Processing Technique ◽

Advanced Materials ◽

Host Matrix ◽

Digital Light Processing ◽

Three Dimensional Printing

Abstract The convergence of 3D printing techniques and nanomaterials is generating a compelling opportunity space to create advanced materials with multiscale structural control and hierarchical functionalities. While most nanoparticles consist of a dense material, less attention has been payed to 3D printing of nanoparticles with intrinsic porosity. Here, we combine ultrasmall (about 10 nm) silica nanocages with digital light processing technique for the direct 3D printing of hierarchically porous parts with arbitrary shapes, as well as tunable internal structures and high surface area. Thanks to the versatile and orthogonal cage surface modifications, we show how this approach can be applied for the implementation and positioning of functionalities throughout 3D printed objects. Furthermore, taking advantage of the internal porosity of the printed parts, an internal printing approach is proposed for the localized deposition of a guest material within a host matrix, enabling complex 3D material designs.

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Layered 3D Printing by Tethered Pyro-Electrospinning

Advances in Polymer Technology ◽

10.1155/2020/1252960 ◽

2020 ◽

Vol 2020 ◽

pp. 1-9 ◽

Cited By ~ 2

Author(s):

Sara Coppola ◽

Giuseppe Nasti ◽

Veronica Vespini ◽

Pietro Ferraro

Keyword(s):

3D Printing ◽

Three Dimensional ◽

Multiwall Carbon Nanotubes ◽

Processing Parameters ◽

Layer By Layer ◽

Biocompatible Polymer ◽

Intrinsic Factors ◽

Electric Effect ◽

Mild Temperature

Nowadays it is easy to imagine that the exploitation of different additive manufacturing approaches could find use in regenerative medicine and frontiers nanotechnology with a strong interest in the development of in vivo bio-incubators that better replicate the tissue environment. Various electrospinning technologies have been exploited for the fabrication of composite polymeric architectures, where fibers have been used for the construction layer by layer of micro-architectures. Unfortunately, in case of processing biomaterials, the intrinsic factors of the materials could become obstacles when considering such advanced engineering methods. Here, for the first time, we use the pyro-EHD process for the fabrication of layered three-dimensional architectures made using a biodegradable and biocompatible polymer. The proposed approach for layered 3D printing works at mild temperature allowing deposition at high resolution and great flexibility in manufacturing, avoiding high voltage generators, and nozzles. The layered 3D printing, activated by the pyro-electric effect, is discussed and characterized in terms of geometrical features and processing parameters. Different geometries and micro-architecture (wall, square, triangle, and hybrid structures) have been demonstrated and over printing of composite polymer, obtained by mixing multiwall carbon nanotubes and fluorochrome, has been discussed, focusing on the use of a biodegradable and biocompatible polymer.

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Characterization and Fabrication of ABS and PLA-Based Polymer Matrix Composites Using 3D Printing

Springer Proceedings in Materials - Advances in Materials Research ◽

10.1007/978-981-15-8319-3_50 ◽

2021 ◽

pp. 499-510

Author(s):

Anandha Moorthy Appusamy ◽

E. Prakash ◽

S. Madheswaran ◽

Arunkumar Rajamanickam ◽

Vinoth Kumar Selvakumar ◽

...

Keyword(s):

3D Printing ◽

Polymer Matrix ◽

Polymer Matrix Composites ◽

Matrix Composites

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Grayscale digital light processing 3D printing for highly functionally graded materials

Science Advances ◽

10.1126/sciadv.aav5790 ◽

2019 ◽

Vol 5 (5) ◽

pp. eaav5790 ◽

Cited By ~ 54

Author(s):

Xiao Kuang ◽

Jiangtao Wu ◽

Kaijuan Chen ◽

Zeang Zhao ◽

Zhen Ding ◽

...

Keyword(s):

3D Printing ◽

Functionally Graded Materials ◽

Three Dimensional ◽

Functionally Graded ◽

Advanced Manufacturing ◽

4D Printing ◽

Poor Control ◽

Graded Materials ◽

Digital Light Processing ◽

Direct Fabrication

Three-dimensional (3D) printing or additive manufacturing, as a revolutionary technology for future advanced manufacturing, usually prints parts with poor control of complex gradients for functional applications. We present a single-vat grayscale digital light processing (g-DLP) 3D printing method using grayscale light patterns and a two-stage curing ink to obtain functionally graded materials with the mechanical gradient up to three orders of magnitude and high resolution. To demonstrate the g-DLP, we show the direct fabrication of complex 2D/3D lattices with controlled buckling and deformation sequence, negative Poisson’s ratio metamaterial, presurgical models with stiffness variations, composites for 4D printing, and anti-counterfeiting 3D printing.

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3D Printing of Amino Resin-based Photosensitive Materials on Multi-parameter Optimization Design for Vascular Engineering Applications

Polymers ◽

10.3390/polym11091394 ◽

2019 ◽

Vol 11 (9) ◽

pp. 1394 ◽

Cited By ~ 10

Author(s):

Yung-Cheng Chiu ◽

Yu-Fang Shen ◽

Alvin Kai-Xing Lee ◽

Shu-Hsien Lin ◽

Yu-Chen Wu ◽

...

Keyword(s):

Cardiovascular Diseases ◽

3D Printing ◽

Optimization Design ◽

Cellular Proliferation ◽

Vascular Grafts ◽

Treatment Method ◽

Processing Parameters ◽

Cellular Adhesion ◽

Digital Light Processing ◽

Amino Resin

Cardiovascular diseases are currently the most common cause of death globally and of which, the golden treatment method for severe cardiovascular diseases or coronary artery diseases are implantations of synthetic vascular grafts. However, such grafts often come with rejections and hypersensitivity reactions. With the emergence of regenerative medicine, researchers are now trying to explore alternative ways to produce grafts that are less likely to induce immunological reactions in patients. The main goal of such studies is to produce biocompatible artificial vascular grafts with the capability of allowing cellular adhesion and cellular proliferation for tissues regeneration. The Design of Experimental concepts is employed into the manufacturing process of digital light processing (DLP) 3D printing technology to explore near-optimal processing parameters to produce artificial vascular grafts with vascular characteristics that are close to native vessels by assessing for the cause and effect relationships between different ratios of amino resin (AR), 2-hydroxyethyl methacrylate (HEMA), dopamine, and curing durations. We found that with proper optimization of fabrication procedures and ratios of materials, we are able to successfully fabricate vascular grafts with good printing resolutions. These had similar physical properties to native vessels and were able to support cellular adhesion and proliferation. This study could support future studies in exploring near-optimal processes for fabrication of artificial vascular grafts that could be adapted into clinical applications.

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Three-Dimensional Printable Nanoporous Polymer Matrix Composites for Daytime Radiative Cooling

Nano Letters ◽

10.1021/acs.nanolett.0c04810 ◽

2021 ◽

Vol 21 (3) ◽

pp. 1493-1499

Author(s):

Kai Zhou ◽

Wei Li ◽

Bijal Bankim Patel ◽

Ran Tao ◽

Yilong Chang ◽

...

Keyword(s):

Polymer Matrix ◽

Polymer Matrix Composites ◽

Three Dimensional ◽

Radiative Cooling ◽

Matrix Composites

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Cytocompatibility of 3D printed dental materials for temporary restorations on fibroblasts

10.21203/rs.2.21028/v1 ◽

2020 ◽

Author(s):

Jung-Hyun Park ◽

Hyun Lee ◽

Jong-Woo Kim ◽

Ji-Hwan Kim

Keyword(s):

3D Printing ◽

Laser Scanning ◽

Dental Materials ◽

Three Dimensional ◽

Confocal Laser Scanning Microscope ◽

Confocal Laser ◽

Control Group ◽

Digital Light Processing ◽

3D Printed ◽

Materials Used

Abstract Background Three-dimensional (3D) printing is widely used in the fabrication of dental prostheses; however, the influence of dental materials used for 3D printing on temporary restoration of fibroblasts in tissues is unclear. Thus, the influence of different dental materials on fibroblasts were investigated. Methods Digital light processing (DLP) type 3D printing was used. Specimens in the control group were fabricated by mixing liquid and powder self-curing resin restoration materials. The temporary resin materials used were Model, Castable, Clear-SG, Tray, and Temporary, and the self-curing resin materials used were Lang dental, Alike, Milky blue, TOKVSO CUREFAST, and UniFast III. Fibroblast cells were cultured on each specimen and subsequently post-treated for analysis. Morphology of the adhered cells were observed using a confocal laser scanning microscope (CLSM) and a scanning electron microscope (SEM). Results CLSM and SEM cell imaging revealed that the 3D printed material group presented better cell adhesion with well-distributed filopodia compared to that in the conventional resin material group. Cell proliferation was significantly higher in the 3D printing materials. Conclusion This indicates that using resins fabricated by 3D printing technology rather than the ones fabricated by self-curing technology is recommended for the fabrication of dental temporary restorations.

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