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Shaping soft hydrogels into 3D, multiscale, perfusable models using multimodal printing.

Puskal Kunwar1, Arun Poudel1, Ujjwal Aryal1

  • 1Department of Biomedical and Chemical Engineering, Syracuse University, Syracuse, NY 13244, United States of America.

Biofabrication
|April 2, 2026
PubMed
Summary
This summary is machine-generated.

This study introduces a novel hybrid 3D printing method combining digital light projection (DLP) and two-photon ablation (TPA) for advanced biofabrication. The technique enables the creation of complex, multiscale hydrogel constructs with integrated perfusable features for organ-on-chip applications.

Keywords:
digital light projectiondigital micromirrorhydrogelmultiscale printingorgan-on-a-chipperfusable channelstwo-photon ablation

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Area of Science:

  • Biomaterials Engineering
  • Biofabrication
  • Microfluidics

Background:

  • Fabricating complex 3D hydrogel structures with multiscale features is challenging.
  • Existing methods like digital light projection (DLP) and two-photon ablation (TPA) have limitations.
  • Soft hydrogel bioinks present unique processing difficulties for complex designs.

Purpose of the Study:

  • To develop a hybrid 3D printing platform combining macroscale DLP and microscale TPA.
  • To overcome limitations in fabricating multiscale, multi-material, and topologically complex soft hydrogel constructs.
  • To create advanced bio-printed structures with integrated perfusable microarchitectures.

Main Methods:

  • Combined additive DLP (macroscale) and subtractive TPA (microscale) 3D printing.
  • Utilized multi-material exchange capability for diverse bioink formulations.
  • Identified and optimized hydrogel bioinks compatible with both DLP and TPA processing modes.
  • Resolved technical challenges in multimodal fabrication, including alignment, soft-hard material integration, and swelling control.

Main Results:

  • Successfully fabricated centimeter-scale hydrogel constructs with embedded microscale perfusable topologies.
  • Demonstrated the creation of complex structures not achievable with isolated DLP or TPA.
  • Fabricated microfluidic chips with independently perfusable channels and dual-fluidic circuits mimicking biological interfaces.
  • Created endothelialized microfluidic channels within complex 3D constructs.

Conclusions:

  • The hybrid DLP-TPA platform offers unprecedented capabilities for fabricating multiscale, perfusable bio-structures.
  • This technology enables the creation of in vivo-like complexities for advanced biological models.
  • Potential applications include the development of next-generation organ-on-chips and tissue engineering scaffolds.