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Long-Fiber Embedded Hydrogel 3D Printing for Structural Reinforcement.

Wenhuan Sun1, Joshua W Tashman2, Daniel J Shiwarski2

  • 1Department of Mechanical Engineering, Carnegie Mellon University, Pittsburgh, Pennsylvania 15213, United States.

ACS Biomaterials Science & Engineering
|December 3, 2021
PubMed
Summary

This study introduces a novel 3D printing method for hydrogels reinforced with embedded fibers, significantly enhancing structural integrity for advanced biomaterial applications. The technique offers improved mechanical properties and design versatility.

Keywords:
FRESH printingfiber embeddinghydrogelmultimaterial printing

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Area of Science:

  • Biomaterials Engineering
  • Additive Manufacturing
  • Soft Robotics

Background:

  • Hydrogels are versatile biomaterials for robotics, microfluidics, and tissue engineering.
  • Existing Freeform Reversible Embedding of Suspended Hydrogels (FRESH) 3D printing enables complex structures but yields low structural rigidity.
  • This limitation restricts FRESH hydrogel applications, particularly in non-aqueous environments.

Purpose of the Study:

  • To develop a 3D printing technique for fiber-reinforced hydrogels with enhanced structural properties.
  • To overcome the limitations of low mechanical rigidity in FRESH-printed hydrogels.
  • To demonstrate the versatility and accessibility of the novel fiber-embedding method.

Main Methods:

  • Utilized a multihead printing platform with a custom fiber extruder and an open-source FRESH bioprinter.
  • Embedded long fibers within hydrogel structures during the 3D printing process.
  • Investigated various fiber types, sizes, and 2D/3D embedding patterns, including nonplanar printing.

Main Results:

  • Achieved significant structural reinforcement, with tensile modulus increasing from 56.78 ± 8.76 to 382.55 ± 25.29 kPa.
  • Tensile strength improved from 9.44 ± 2.28 to 45.05 ± 5.53 kPa.
  • Demonstrated successful embedding of diverse fibers and complex 2D/3D patterns, including a conical helix.

Conclusions:

  • The developed long-fiber embedded hydrogel 3D printing technique substantially enhances structural rigidity.
  • The method is versatile, compatible with various fibers and patterns, and utilizes low-cost, open-source components.
  • This advancement expands the application scope of FRESH hydrogels, particularly for demanding environments and complex designs.