Generation of Controlled Micrometric Fibers inside Printed Scaffolds Using Standard FDM 3D Printers

Area of Science:

• Materials Science
• Additive Manufacturing
• Biomedical Engineering

Background:

• Standard fused deposition modeling (FDM) 3D printers have limited resolution (typically >100 µm), hindering the creation of intricate internal microstructures.
• Advanced techniques like melting electro-writing (MEW) and near-field electrospinning (NFES) can create microfibers but are complex.
• There is a need for methods to fabricate microscopic internal fibers within scaffolds using conventional FDM printers.

Purpose of the Study:

• To investigate the feasibility of creating reproducible microscopic internal fibers inside 3D printed scaffolds using a standard FDM printer.
• To develop novel algorithms and modify printing parameters to achieve sub-100 µm features.
• To analyze the influence of printing conditions on microfiber formation and morphology.

Main Methods:

• Development of custom Python scripts to generate G-code for deposition routines based on geometric primitives.
• Modification of fundamental FDM printing parameters: temperature, speed, and material flow.
• Optical analysis of printed scaffolds using a digital microscope and ImageJ software for quantitative image analysis.

Main Results:

• Achieved the formation of heterogeneously shaped microfilaments with an average diameter of 48 ± 12 µm (mean ± S.D.).
• Identified optimal printing conditions for microfiber generation: high printing speeds and a reduced extrusion multiplier.
• Demonstrated the capability of standard FDM printers to produce microscopic internal structures through algorithmic control.

Conclusions:

• Novel algorithmic strategies enable the reproducible fabrication of microscopic internal fibers within scaffolds using standard FDM 3D printing.
• High printing speeds and reduced extrusion multipliers are critical parameters for achieving desired microfiber dimensions.
• This approach offers a more accessible method for creating complex microstructures in 3D printed scaffolds, potentially advancing applications in tissue engineering and regenerative medicine.