3D printing families: Laser, powder, nozzle based techniques

© 2017 Elsevier Ltd. All rights reserved. Three-dimensional (3D) printing describes a process where the raw material, in a form of powder, liquid or solid filament, is deposited layer-by-layer to build up a physical 3D object. The aim of this chapter is to provide a comprehensive overview of the 3D printing techniques suitable for medical applications. Here we highlight the main innovations and breakthroughs achieved in the past three decades and categorize the additive manufacturing technologies available into resin-, powder-, extrusion-, and droplet-based systems. Additionally, this chapter discusses the recent technological advances and challenges in bioprinting of tissue constructs and organs with a hardware perspective. Bioprinting has been investigated for the fabrication of several biological constructs, ranging from skin, bone, vascular and cartilage tissues, as well as for the fabrication of high-throughput microarrays for toxicological analysis and drug screening. Future development in bioprinting techniques and bioink materials will certainly allow the fabrication of customized tissues and organs.

[1]  Ibrahim T. Ozbolat,et al.  A comprehensive review on droplet-based bioprinting: Past, present and future. , 2016, Biomaterials.

[2]  A. Atala Future trends in bladder reconstructive surgery. , 2002, Seminars in pediatric surgery.

[3]  K. Leong,et al.  Solid freeform fabrication of three-dimensional scaffolds for engineering replacement tissues and organs. , 2003, Biomaterials.

[4]  Hermann Seitz,et al.  Endocultivation: 3D printed customized porous scaffolds for heterotopic bone induction. , 2009, Oral oncology.

[5]  G. Klein,et al.  3D printing and neurosurgery--ready for prime time? , 2013, World neurosurgery.

[6]  Kaufui Wong,et al.  A Review of Additive Manufacturing , 2012 .

[7]  Marc E. Nelson,et al.  Bioresorbable airway splint created with a three-dimensional printer. , 2013, The New England journal of medicine.

[8]  U. Spetzger,et al.  Surgical planning, manufacturing and implantation of an individualized cervical fusion titanium cage using patient-specific data , 2016, European Spine Journal.

[9]  W. Zhong,et al.  Short fiber reinforced composites for fused deposition modeling , 2001 .

[10]  Le Xie,et al.  A novel computer-assisted drill guide template for placement of C2 laminar screws , 2009, European Spine Journal.

[11]  R. Meneghello,et al.  Powder-based 3D printing for bone tissue engineering. , 2016, Biotechnology advances.

[12]  A Piattelli,et al.  Direct laser metal sintering as a new approach to fabrication of an isoelastic functionally graded material for manufacture of porous titanium dental implants. , 2008, Dental materials : official publication of the Academy of Dental Materials.

[13]  Boris N. Chichkov,et al.  Laser Processing of Advanced Bioceramics , 2005 .

[14]  James J. Yoo,et al.  A 3D bioprinting system to produce human-scale tissue constructs with structural integrity , 2016, Nature Biotechnology.

[15]  GasperiniLuca,et al.  An electrohydrodynamic bioprinter for alginate hydrogels containing living cells. , 2015 .

[16]  Dietmar W Hutmacher,et al.  Scaffold-based tissue engineering: rationale for computer-aided design and solid free-form fabrication systems. , 2004, Trends in biotechnology.

[17]  C K Chua,et al.  Selective laser sintering of biocompatible polymers for applications in tissue engineering. , 2005, Bio-medical materials and engineering.

[18]  J. Mireles,et al.  Development of a Fused Deposition Modeling System for Low Melting Temperature Metal Alloys , 2013 .

[19]  Lewis Mullen,et al.  Selective Laser Melting: a regular unit cell approach for the manufacture of porous, titanium, bone in-growth constructs, suitable for orthopedic applications. , 2009, Journal of biomedical materials research. Part B, Applied biomaterials.

[20]  Bin Duan,et al.  Three-dimensional nanocomposite scaffolds fabricated via selective laser sintering for bone tissue engineering. , 2010, Acta biomaterialia.

[21]  R. Osellame,et al.  Two-Photon Laser Polymerization: From Fundamentals to Biomedical Application in Tissue Engineering and Regenerative Medicine , 2012, Journal of applied biomaterials & functional materials.

[22]  M. Leu,et al.  Effect of material, process parameters, and simulated body fluids on mechanical properties of 13-93 bioactive glass porous constructs made by selective laser sintering. , 2012, Journal of the mechanical behavior of biomedical materials.

[23]  M. von Walter,et al.  Structural, mechanical and in vitro characterization of individually structured Ti-6Al-4V produced by direct laser forming. , 2006, Biomaterials.

[24]  Maria Farsari,et al.  Direct laser writing , 2015 .

[25]  Guifang Gao,et al.  Accelerated myotube formation using bioprinting technology for biosensor applications , 2012, Biotechnology Letters.

[26]  Shoufeng Yang,et al.  Freeform fabrication of nanobiomaterials using 3D printing , 2014 .

[27]  Antonios G Mikos,et al.  Biodegradable fumarate-based polyHIPEs as tissue engineering scaffolds. , 2007, Biomacromolecules.

[28]  Dichen Li,et al.  Microstructure and mechanical properties of TiAl-based composites prepared by Stereolithography and gelcasting technologies , 2015 .

[29]  Sanjna Nayar,et al.  Rapid prototyping and stereolithography in dentistry , 2015, Journal of pharmacy & bioallied sciences.

[30]  Colleen L Flanagan,et al.  Bone tissue engineering using polycaprolactone scaffolds fabricated via selective laser sintering. , 2005, Biomaterials.

[31]  Alan Faulkner-Jones,et al.  Development of a valve-based cell printer for the formation of human embryonic stem cell spheroid aggregates , 2013, Biofabrication.

[32]  Ronan M. T. Fleming,et al.  Advantages and challenges of microfluidic cell culture in polydimethylsiloxane devices. , 2015, Biosensors & bioelectronics.

[33]  Margam Chandrasekaran,et al.  Rapid prototyping in tissue engineering: challenges and potential. , 2004, Trends in biotechnology.

[34]  M. Gu,et al.  Two-photon polymerisation for three-dimensional micro-fabrication , 2006 .

[35]  Omar Ahmed Mohamed,et al.  Optimization of fused deposition modeling process parameters: a review of current research and future prospects , 2015, Advances in Manufacturing.

[36]  J. Urry,et al.  3D, SF and the future , 2013 .

[37]  Xiaofeng Cui,et al.  Thermal inkjet printing in tissue engineering and regenerative medicine. , 2012, Recent patents on drug delivery & formulation.

[38]  M. Padgett,et al.  Development of a 3D printer using scanning projection stereolithography , 2015, Scientific Reports.

[39]  Xue Yan,et al.  PII: 0010-4485(95)00035-6 , 2003 .

[40]  Harri Korhonen,et al.  Preparation of poly(ε-caprolactone)-based tissue engineering scaffolds by stereolithography. , 2011, Acta biomaterialia.

[41]  D. Hutmacher,et al.  Osteogenic induction of human bone marrow-derived mesenchymal progenitor cells in novel synthetic polymer-hydrogel matrices. , 2003, Tissue engineering.

[42]  Syed H. Masood,et al.  Development of new metal/polymer materials for rapid tooling using Fused deposition modelling , 2004 .

[43]  Masaki Tsuchiya,et al.  Microfluidic devices fabricated using stereolithography for preparation of monodisperse double emulsions , 2016 .

[44]  A. Piskarskas,et al.  Ultrafast laser nanostructuring of photopolymers: a decade of advances , 2013 .

[45]  Chien-Tzung Chen,et al.  Surface modification of polycaprolactone scaffolds fabricated via selective laser sintering for cartilage tissue engineering. , 2014, Materials science & engineering. C, Materials for biological applications.

[46]  Rocky S Tuan,et al.  Application of visible light-based projection stereolithography for live cell-scaffold fabrication with designed architecture. , 2013, Biomaterials.

[47]  M. Mehrali,et al.  A review on powder-based additive manufacturing for tissue engineering: selective laser sintering and inkjet 3D printing , 2015, Science and technology of advanced materials.

[48]  E. O. Olakanmi,et al.  A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties , 2015 .

[49]  Sailing He,et al.  Rapid Fabrication of Complex 3D Extracellular Microenvironments by Dynamic Optical Projection Stereolithography , 2012, Advanced materials.

[50]  Rolf Mülhaupt,et al.  Desktop manufacturing of complex objects, prototypes and biomedical scaffolds by means of computer‐assisted design combined with computer‐guided 3D plotting of polymers and reactive oligomers , 2000 .

[51]  E. Saiz,et al.  Robocasting of Structural Ceramic Parts with Hydrogel Inks , 2016 .

[52]  K E Tanner,et al.  Selective Laser Sintering of Hydroxyapatite Reinforced Polyethylene Composites for Bioactive Implants and Tissue Scaffold Development , 2006, Proceedings of the Institution of Mechanical Engineers. Part H, Journal of engineering in medicine.

[53]  Krishnendu Roy,et al.  A digital micro-mirror device-based system for the microfabrication of complex, spatially patterned tissue engineering scaffolds. , 2006, Journal of biomedical materials research. Part A.

[54]  Dong-Woo Cho,et al.  Development of nano- and microscale composite 3D scaffolds using PPF/DEF-HA and micro-stereolithography , 2009 .

[55]  S. Dandekeri,et al.  Stereolithographic surgical template: a review. , 2013, Journal of clinical and diagnostic research : JCDR.

[56]  Jianzhong Fu,et al.  Freeform inkjet printing of cellular structures with bifurcations , 2015, Biotechnology and bioengineering.

[57]  Keekyoung Kim,et al.  3D bioprinting for engineering complex tissues. , 2016, Biotechnology advances.

[58]  C. P. Purssell,et al.  A miniature flow sensor fabricated by micro-stereolithography employing a magnetite/acrylic nanocomposite resin , 2011 .

[59]  U. Demirci,et al.  Bioprinting for stem cell research. , 2013, Trends in biotechnology.

[60]  Dong-Woo Cho,et al.  Solid Free-form Fabrication Technology and Its Application to Bone Tissue Engineering. , 2010, International journal of stem cells.

[61]  Sophie C Cox,et al.  3D printing of porous hydroxyapatite scaffolds intended for use in bone tissue engineering applications. , 2015, Materials science & engineering. C, Materials for biological applications.

[62]  I. Zein,et al.  Fused deposition modeling of novel scaffold architectures for tissue engineering applications. , 2002, Biomaterials.

[63]  Dong-Woo Cho,et al.  Microstereolithography-based computer-aided manufacturing for tissue engineering. , 2012, Methods in molecular biology.

[64]  Hermann Seitz,et al.  A review on 3D micro-additive manufacturing technologies , 2012, The International Journal of Advanced Manufacturing Technology.

[65]  Brian Derby,et al.  Bioprinting: Inkjet printing proteins and hybrid cell-containing materials and structures , 2008 .

[66]  Nils-Claudius Gellrich,et al.  Bone repair by cell-seeded 3D-bioplotted composite scaffolds made of collagen treated tricalciumphosphate or tricalciumphosphate-chitosan-collagen hydrogel or PLGA in ovine critical-sized calvarial defects. , 2010, Journal of biomedical materials research. Part B, Applied biomaterials.

[67]  U. Demirci,et al.  Acoustic picoliter droplets for emerging applications in semiconductor industry and biotechnology , 2006, Journal of Microelectromechanical Systems.

[68]  B. Derby,et al.  Inkjet printing biomaterials for tissue engineering: bioprinting , 2014 .

[69]  B. Rath,et al.  Evaluation of implant position and knee alignment after patient-specific unicompartmental knee arthroplasty. , 2011, The Knee.

[70]  Ventola Cl Medical Applications for 3D Printing: Current and Projected Uses. , 2014 .

[71]  A.C.W. Lau,et al.  Precision extruding deposition and characterization of cellular poly‐ε‐caprolactone tissue scaffolds , 2004 .

[72]  H. Wijshoff,et al.  The dynamics of the piezo inkjet printhead operation , 2010 .

[73]  Adir Cohen,et al.  Mandibular reconstruction using stereolithographic 3-dimensional printing modeling technology. , 2009, Oral surgery, oral medicine, oral pathology, oral radiology, and endodontics.

[74]  Luis Matey,et al.  PolyJet technology for product prototyping: Tensile strength and surface roughness properties , 2014 .

[75]  A. Bandyopadhyay,et al.  Bone tissue engineering using 3D printing , 2013 .

[76]  Matthias Dipl Ing Greul,et al.  Fast, functional prototypes via multiphase jet solidification , 1995 .

[77]  Omar Ahmed Mohamed,et al.  Optimization of fused deposition modeling process parameters for dimensional accuracy using I-optimality criterion , 2016 .

[78]  T. Boland,et al.  Human microvasculature fabrication using thermal inkjet printing technology. , 2009, Biomaterials.

[79]  U. Demirci,et al.  Single cell epitaxy by acoustic picolitre droplets. , 2007, Lab on a chip.

[80]  Malcolm N. Cooke,et al.  Use of stereolithography to manufacture critical-sized 3D biodegradable scaffolds for bone ingrowth. , 2003, Journal of biomedical materials research. Part B, Applied biomaterials.

[81]  Dhruv R. Seshadri,et al.  A Review of Three-Dimensional Printing in Tissue Engineering. , 2016, Tissue engineering. Part B, Reviews.

[82]  Jordan S. Miller,et al.  Open-Source Selective Laser Sintering (OpenSLS) of Nylon and Biocompatible Polycaprolactone , 2016, PloS one.

[83]  D W Hutmacher,et al.  The effect of rhBMP-2 on canine osteoblasts seeded onto 3D bioactive polycaprolactone scaffolds. , 2004, Biomaterials.

[84]  Tao Xu,et al.  Fabrication and characterization of bio-engineered cardiac pseudo tissues , 2009, Biofabrication.

[85]  Scott J. Hollister,et al.  Mitigation of tracheobronchomalacia with 3D-printed personalized medical devices in pediatric patients , 2015, Science Translational Medicine.

[86]  Douglas C. Montgomery,et al.  Optimizing stereolithography throughput , 1997 .

[87]  D. D’Lima,et al.  Direct human cartilage repair using three-dimensional bioprinting technology. , 2012, Tissue engineering. Part A.

[88]  R. Landers,et al.  Rapid prototyping of scaffolds derived from thermoreversible hydrogels and tailored for applications in tissue engineering. , 2002, Biomaterials.

[89]  Anthony Atala,et al.  3D bioprinting of tissues and organs , 2014, Nature Biotechnology.

[90]  Benjamin M Wu,et al.  Recent advances in 3D printing of biomaterials , 2015, Journal of Biological Engineering.

[91]  Kang Zhang,et al.  3D printing of functional biomaterials for tissue engineering. , 2016, Current opinion in biotechnology.

[92]  L. Froyen,et al.  Lasers and materials in selective laser sintering , 2002 .

[93]  W Cris Wilson,et al.  Cell and organ printing 1: protein and cell printers. , 2003, The anatomical record. Part A, Discoveries in molecular, cellular, and evolutionary biology.

[94]  Michael Schmidt,et al.  Selective laser sintering of PEEK , 2007 .

[95]  On-chip microfabrication of thermally controllable PNIPAAm microvalves by using optical maskless stereolithography , 2016 .

[96]  José M.F. Ferreira,et al.  Robocasting of 45S5 bioactive glass scaffolds for bone tissue engineering , 2014 .

[97]  André van der Merwe,et al.  Patient‐specific intervertebral disc implants using rapid manufacturing technology , 2013 .

[98]  Paul G. McMenamin,et al.  Emerging Applications of Bedside 3D Printing in Plastic Surgery , 2015, Front. Surg..

[99]  P. Marquis,et al.  Selective laser sintering of ultra high molecular weight polyethylene for clinical applications. , 2000, Journal of biomedical materials research.

[100]  Denis Evseenko,et al.  TGF-β1 conjugated chitosan collagen hydrogels induce chondrogenic differentiation of human synovium-derived stem cells , 2015, Journal of Biological Engineering.

[101]  Matthew Whitaker,et al.  The history of 3D printing in healthcare , 2014 .

[102]  Katia Bertoldi,et al.  Mathematically defined tissue engineering scaffold architectures prepared by stereolithography. , 2010, Biomaterials.

[103]  Duc Truong Pham,et al.  A comparison of rapid prototyping technologies , 1998 .

[104]  B. Duan,et al.  3D bioprinting of heterogeneous aortic valve conduits with alginate/gelatin hydrogels. , 2013, Journal of biomedical materials research. Part A.

[105]  F. Melchels,et al.  A review on stereolithography and its applications in biomedical engineering. , 2010, Biomaterials.

[106]  Rainer Schmelzeisen,et al.  Fabrication of soft tissue engineering scaffolds by means of rapid prototyping techniques , 2002 .

[107]  David L. Kaplan,et al.  Direct‐Write Assembly of Microperiodic Silk Fibroin Scaffolds for Tissue Engineering Applications , 2008 .

[108]  R. Markwald,et al.  Scaffold‐free inkjet printing of three‐dimensional zigzag cellular tubes , 2012, Biotechnology and bioengineering.