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Optimization of photocrosslinkable resin components and 3D printing process parameters
Antonio J Guerra1, Jan Lammel-Lindemann2, Alex Katko3
1Mechanical Engineering and Industrial Construction, Universitat de Girona, Girona, Spain; Department of Plastic and Reconstructive Surgery, The Ohio State University, Columbus, OH 43210, United States.
Acta Biomaterialia
|July 29, 2019
Summary
Optimizing 3D printing resins with poly(propylene fumarate) (PPF) and ethyl acetate (EA) improves scaffold printing success and biocompatibility. Higher PPF content enhances printability, while EA offers a safer alternative to diethyl fumarate (DEF).
Area of Science:
- Biomaterials Engineering
- Additive Manufacturing
- Polymer Chemistry
Background:
- Photocrosslink-based 3D printing of resorbable polymers is advancing in the biomedical field.
- Optimization of resin components and printing parameters is crucial for successful scaffold fabrication.
- Further research is needed on photocuring stereochemistry, novel resin additives, and polymer components.
Purpose of the Study:
- To analyze the effects of poly(propylene fumarate) (PPF) resin components on 3D printing process parameters.
- To investigate the impact of novel resin components, including ethyl acetate (EA), on PPF resin properties and printability.
- To establish a systematic approach for optimizing resin composition and 3D printing parameters for resorbable scaffolds.
Main Methods:
- Investigated resin components: poly(propylene fumarate) (PPF), diethyl fumarate (DEF), bisacylphosphine oxide (BAPO), Irgacure 784, 2-hydroxy-4-methoxybenzophenone (HMB), and ethyl acetate (EA).
- Studied printing parameters: Exposure Time, Voxel Depth, and Overcuring Depth.
- Employed Taguchi Design of Experiments to optimize resin concentrations and printing parameters for 3D printable PPF resins.
- Conducted preliminary in vitro cytotoxicity tests (ISO 10993-5) to assess biocompatibility.
Main Results:
- Resins with higher polymer cross-link density (higher PPF content) exhibited improved printability at greater voxel depths and higher success rates.
- Higher voxel depth accelerates printing, provided resolution is maintained; optimal printing depends on the balance between voxel depth and overcuring depth.
- Ethyl acetate (EA) demonstrated superior performance and biocompatibility compared to diethyl fumarate (DEF), with no reduction in scaffold biocompatibility.
Conclusions:
- Optimized PPF resin formulations and printing parameters enhance the 3D printing of resorbable scaffolds.
- Ethyl acetate (EA) is a promising, biocompatible alternative to diethyl fumarate (DEF) in biomedical 3D printing resins.
- The developed workpath for resin optimization and photocrosslinkable process optimization provides a systematic method for fabricating complex porous scaffolds.
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