A Multi-Component Polymeric Bioink Formulation developed Using an In-House Integrated Bioextruder

Advancements in 3D printing have revolutionised tissue engineering by enabling the fabrication of biomimetic scaffolds with greater precision and functionality. However, current bio-inks are often limited by suboptimal printability, insufficient mechanical stability, and a lack of comprehensive mechanistic understanding of structure-property-performance relationships. To address these challenges, the present study develops a novel multi-component bio-ink integrated with a custom bio-extrusion strategy to enhance scaffold fidelity and functional performance. The present study introduces a novel multi-component bio-ink formulation with polyvinyl alcohol (PVA), gelatin (Gel), sodium alginate (SA), and polyether ketone (PEK) that achieves a rare combination of optimal printability, mechanical robustness, and structural fidelity in 3D-printed constructs. The ink was prepared by dissolving in their respective solvents under controlled conditions. A customised bio-extruder head, integrated into a Creality Ender 3D printer, enabled precise ink deposition via a plunger-driven system with dynamic calibration for consistent material flow. This cost-effective modification enhances the accuracy of scaffold fabrication, offering new possibilities for regenerative medicine. Sixteen ink formulations were assessed based on their rheological behaviour, extrusion ability, layer adhesion, and mechanical performance. Composition 1, with an optimised balance of PVA (2.5%), Gel (0.5%), SA (0.25%), and PEK (0.5%), demonstrated superior printability, structural integrity, and mechanical stability, making it suitable for scaffold fabrication.