Static Compressive Behavior and Material Failure Mechanism of Trabecular Tantalum Scaffolds Fabricated by Laser Powder Bed Fusion-based Additive Manufacturing

Additively manufactured trabecular tantalum (Ta) scaffolds are promising bone repair materials for load-bearing applications due to their good pore interconnectivity. However, a thorough mechanical behavior evaluation is required before conducting animal studies and clinical research using these scaffolds. In this study, we revealed the compressive mechanical behavior and material failure mechanism of trabecular tantalum scaffolds by compression testing, finite element analysis (FEA), and scanning electron microscopy (SEM). Trabecular tantalum scaffolds with porosities of 65%, 75%, and 85% were fabricated by laser powder bed fusion-based additive manufacturing. Porosity has a significant effect on their compressive mechanical properties. As the porosity decreased from 85% to 65%, the compressive yield strength and elastic modulus increased from 11.9 MPa to 35.7 MPa and 1.1 GPa to 3.0 GPa, respectively. Compression testing results indicate that trabecular tantalum scaffolds demonstrate ductile deformation and excellent mechanical reliability. No macroscopic cracks were found when they were subjected to strain up to 50%. SEM observations showed that material failure results from tantalum strut deformation and fracture. Most microcracks occurred at conjunctions, whereas few of them appear on the struts. FEA-generated compressive stress distribution and material deformation were consistent with experimental results. Stress concentrates at strut conjunctions and vertical struts, where fractures occur during compression testing, indicating that the load-bearing capability of trabecular tantalum scaffolds can be enhanced by strengthening strut conjunctions and vertical struts. Therefore, additively manufactured trabecular tantalum scaffolds can be used in bone tissue reconstruction applications.

Preparation of Graphene Oxide-loaded Nickel with Excellent Antibacterial Property by Magnetic Field-Assisted Scanning Jet Electrodeposition

Graphene oxide (GO) is recognized as a promising antibacterial material that is expected to be used to prepare a new generation of high-efficiency antibacterial coatings. The propensity of GO to agglomeration makes it difficult to apply it effectively. A new method of preparing GO-loaded nickel (GNC) with excellent antibacterial property is proposed in this paper. In this work, GNC was prepared on a titanium sheet by magnetic field-assisted scanning jet electrodeposition. The massive introduction of GO on the coating was proven by energy disperse spectroscopy and Raman spectroscopy. The antibacterial performance of GNC was proven by agar plate assessment and cell living/dead staining. The detection of intracellular reactive oxygen species (ROS) and the concentration of nickel ions, indicate that the antibacterial property of GNC are not entirely derived from the nickel ions released by the coating and the intracellular ROS induced by nickel ions, but rather are due to the synergistic effect of nickel ions and GO.

Using Spheroids as Building Blocks Towards 3D Bioprinting of Tumor Microenvironment

Cancer still ranks as a leading cause of mortality worldwide. Although considerable efforts have been dedicated to anticancer therapeutics, progress is still slow, partially due to the absence of robust prediction models. Multicellular tumor spheroids, as a major three-dimensional (3D) culture model exhibiting features of avascular tumors, gained great popularity in pathophysiological studies and high throughput drug screening. However, limited control over cellular and structural organization is still the key challenge in achieving in vivo like tissue microenvironment. 3D bioprinting has made great strides toward tissue/organ mimicry, due to its outstanding spatial control through combining both cells and materials, scalability, and reproducibility. Prospectively, harnessing the power from both 3D bioprinting and multicellular spheroids would likely generate more faithful tumor models and advance our understanding on the mechanism of tumor progression. In this review, the emerging concept on using spheroids as a building block in 3D bioprinting for tumor modeling is illustrated. We begin by describing the context of the tumor microenvironment, followed by an introduction of various methodologies for tumor spheroid formation, with their specific merits and drawbacks. Thereafter, we present an overview of existing 3D printed tumor models using spheroids as a focus. We provide a compilation of the contemporary literature sources and summarize the overall advancements in technology and possibilities of using spheroids as building blocks in 3D printed tissue modeling, with a particular emphasis on tumor models. Future outlooks about the wonderous advancements of integrated 3D spheroidal printing conclude this review.

Evaluation of Printing Parameters on 3D Extrusion Printing of Pluronic Hydrogels and Machine Learning Guided Parameter Recommendation

Bioprinting is an emerging technology for the construction of complex three-dimensional (3D) constructs used in various biomedical applications. One of the challenges in this field is the delicate manipulation of material properties and various disparate printing parameters to create structures with high fidelity. Understanding the effects of certain parameters and identifying optimal parameters for creating highly accurate structures are therefore a worthwhile subject to investigate. The objective of this study is to investigate high-impact print parameters on the printing printability and develop a preliminary machine learning model to optimize printing parameters. The results of this study will lead to an exploration of machine learning applications in bioprinting and to an improved understanding between 3D printing parameters and structural printability. Reported results include the effects of rheological property, nozzle gauge, nozzle temperature, path height, and ink composition on the printability of Pluronic F127. The developed Support Vector Machine model generated a process map to assist the selection of optimal printing parameters to yield high quality prints with high probability (>75%). Future work with more generalized machine learning models in bioprinting is also discussed in this article. The finding of this study provides a simple tool to improve printability of extrusion-based bioprinting with minimum experimentations.

Advances in Filament Structure of 3D Bioprinted Biodegradable Bone Repair Scaffolds

Conventional bone repair scaffolds can no longer meet the high standards and requirements of clinical applications in terms of preparation process and service performance. Studies have shown that the diversity of filament structures of implantable scaffolds is closely related to their overall properties (mechanical properties, degradation properties, and biological properties). To better elucidate the characteristics and advantages of different filament structures, this paper retrieves and summarizes the state of the art in the filament structure of the three-dimensional (3D) bioprinted biodegradable bone repair scaffolds, mainly including single-layer structure, double-layer structure, hollow structure, core-shell structure and bionic structures. The eximious performance of the novel scaffolds was discussed from different aspects (material composition, ink configuration, printing parameters, etc.). Besides, the additional functions of the current bone repair scaffold, such as chondrogenesis, angiogenesis, anti-bacteria, and anti-tumor, were also concluded. Finally, the paper prospects the future material selection, structural design, functional development, and performance optimization of bone repair scaffolds.

Toward Mass Customization Through Additive Manufacturing: An Automated Design Pipeline for Respiratory Protective Equipment Validated Against 205 Faces

Respiratory protective equipment (RPE) is traditionally designed through anthropometric sizing to enable mass production. However, this can lead to long-standing problems of low-compliance, severe skin trauma, and higher fit test failure rates among certain demographic groups, particularly females and non-white ethnic groups. Additive manufacturing could be a viable solution to produce custom-fitted RPE, but the manual design process is time-consuming, cost-prohibitive and unscalable for mass customization. This paper proposes an automated design pipeline which generates the computer-aided design models of custom-fit RPE from unprocessed three-dimensional (3D) facial scans. The pipeline successfully processed 197 of 205 facial scans with <2 min/scan. The average and maximum geometric error of the mask were 0.62 mm and 2.03 mm, respectively. No statistically significant differences in mask fit were found between male and female, Asian and White, White and Others, Healthy and Overweight, Overweight and Obese, Middle age, and Senior groups.

Development of a Multi-Material 3D Printer for Functional Anatomic Models

Anatomic models are important in medical education and pre-operative planning as they help students or doctors prepare for real scenarios in a risk-free way. Several experimental anatomic models were made with additive manufacturing techniques to improve geometric, radiological, or mechanical realism. However, reproducing the mechanical behavior of soft tissues remains a challenge. To solve this problem, multi-material structuring of soft and hard materials was proposed in this study, and a three-dimensional (3D) printer was built to make such structuring possible. The printer relies on extrusion to deposit certain thermoplastic and silicone rubber materials. Various objects were successfully printed for testing the feasibility of geometric features such as thin walls, infill structuring, overhangs, and multi-material interfaces. Finally, a small medical image-based ribcage model was printed as a proof of concept for anatomic model printing. The features enabled by this printer offer a promising outlook on mimicking the mechanical properties of various soft tissues.

Cellulose Nanocrystal-Enhanced Thermal-Sensitive Hydrogels of Block Copolymers for 3D Bioprinting

The hydrogel formed by polyethylene glycol-aliphatic polyester block copolymers is an ideal bioink and biomaterial ink for three-dimensional (3D) bioprinting because of its unique temperature sensitivity, mild gelation process, good biocompatibility, and biodegradability. However, the gel forming mechanism based only on hydrophilic-hydrophobic interaction renders the stability and mechanical strength of the formed hydrogels insufficient, and cannot meet the requirements of extrusion 3D printing. In this study, cellulose nanocrystals (CNC), which is a kind of rigid, hydrophilic, and biocompatible nanomaterial, were introduced to enhance the hydrogels so as to meet the requirements of extrusion 3D printing. First, a series of poly(ε-caprolactone/lactide)-b-poly(ethylene glycol)-b-poly(ε-caprolactone/ lactide) (PCLA-PEG-PCLA) triblock copolymers with different molecular weights were prepared. The thermodynamic and rheological properties of CNC-enhanced hydrogels were investigated. The results showed that the addition of CNC significantly improved the thermal stability and mechanical properties of the hydrogels, and within a certain range, the enhancement effect was directly proportional to the concentration of CNC. More importantly, the PCLA-PEG-PCLA hydrogels enhanced by CNC could be extruded and printed through temperature regulation. The printed objects had high resolution and fidelity with effectively maintained structure. Moreover, the hydrogels have good biocompatibility with a high cell viability. Therefore, this is a simple and effective strategy. The addition of the hydrophilic rigid nanoparticles such as CNC improves the mechanical properties of the soft hydrogels which made it able to meet the requirements of 3D bioprinting.

Custom Shoe Sole Design and Modeling Toward 3D Printing

This study introduces a design procedure for improving an individual’s footwear comfort with body weight index and activity requirements by customized three-dimensional (3D)-printed shoe midsole lattice structure. This method guides the selection of customized 3D-printed fabrications incorporating both physical and geometrical properties that meet user demands. The analysis of the lattice effects on minimizing the stress on plantar pressure was performed by initially creating various shoe midsole lattice structures designed. An appropriate common 3D printable material was selected along with validating its viscoelastic properties using finite element analysis. The lattice structure designs were analyzed under various loading conditions to investigate the suitability of the method in fabricating a customized 3D-printed shoe midsole based on the individual’s specifications using a single material with minimum cost, time, and material use.

3D Topology Optimization and Mesh Dependency for Redesigning Locking Compression Plates Aiming to Reduce Stress Shielding

Current fixation plates for bone fracture treatments are built with biocompatible metallic materials such as stainless steel, titanium, and its alloys (e.g., Ti6Al4V). The stiffness mismatch between the metallic material of the plate and the host bone leads to stress shielding phenomena, bone loss, and healing deficiency. This paper explores the use of three dimensional topology-optimization, based on compliance (i.e., strain energy) minimization, reshaping the design domain of three locking compression plates (four-screw holes, six-screw holes, and eight-screw holes), considering different volume reductions (25, 45, and 75%) and loading conditions (bending, compression, torsion, and combined loads). A finite-element study was also conducted to measure the stiffness of each optimized plate. Thirty-six designs were obtained. Results showed that for a critical value of volume reductions, which depend on the load condition and number of screws, it is possible to obtain designs with lower stiffness, thereby reducing the risk of stress shielding.