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Rheology Indicators for Assessing Bead Spreading of Hydrogels with Functional Rheology Modifiers for Direct Ink

Daniel Alves Heinze^1,2,3, Supreet Thale^1,3, Yimin Yao^1,2

¹Macromolecules Innovation Institute, Virginia Tech, 240 W Campus Dr, Blacksburg, Virginia 24061, United States.

ACS Applied Polymer Materials

|October 2, 2025

Summary

This summary is machine-generated.

This study explores chitosan hydrogels with graphene and titanium dioxide for 3D printing. Optimal rheology, indicated by tan delta, ensures good shape retention and extrusion fidelity in direct ink writing.

Keywords:

3D printing hydrogels material extrusion additive manufacturing particle reinforcement polymer-matrix suspensions rheology

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Area of Science:

Materials Science
Additive Manufacturing
Rheology

Background:

Chitosan hydrogels are promising for additive manufacturing.
Functional fillers like graphene and titanium dioxide can modify hydrogel properties.
Controlling rheology is crucial for successful direct ink writing (DIW).

Purpose of the Study:

To investigate the rheological behavior of chitosan hydrogels with graphene and titanium dioxide fillers.
To establish a design space for rheology modification and bead spreading in DIW.
To understand the impact of formulation components on extrudability and shape retention.

Main Methods:

Rheological testing of chitosan (CS) hydrogel formulations with graphene and titanium dioxide (TiO2) fillers.
Direct ink writing (DIW) additive manufacturing (AM) experiments.
Analysis of printed bead shape and extrusion fidelity.

Main Results:

Tan delta was identified as a key indicator for shape retention; tan delta > 1 resulted in ink spreading.
Formulations with solid-like behavior (tan delta ≤ 1) and low-to-intermediate TiO2 concentrations showed good extrusion and shape retention.
High TiO2 concentrations (25 wt%) led to inconsistent extrusion and reduced fidelity.
Chitosan content influenced structural recovery more favorably than filler addition.

Conclusions:

Rheology modification using functional particles is critical for DIW of hydrogel composites.
Optimizing filler concentration and understanding rheological parameters like tan delta improves extrusion and shape fidelity.
This research provides insights for efficient production of polymer-based hydrogel inks via DIW.