Weijian Hua

Creating multilayered channels for mimicking human blood vessels in thick tissues is the main challenge to overcome in organ biofabrication. Current three-dimensional (3D) printing strategies cannot effectively manufacture hollow channels with multiple layers. This study aims to propose a coaxial nozzle-assisted embedded 3D printing method in which core–shell filaments can be formed in a yield-stress matrix bath by extruding different ink materials through the corresponding channels. The materials selected for the core ink, shell ink, and matrix bath are Pluronic F127 (F127) and calcium chloride (CaCl2), sodium alginate (NaAlg), and poly(ethylene glycol) diacrylate (PEGDA) and nanoclay, respectively. After crosslinking the matrix bath and shell, the core layer made from the sacrificial ink (F127) is removed to generate a single-layered, hollow channel. In this work, the effects of ink material properties and operating conditions on core–shell filament formation have been systematically studied. The rheological and mechanical properties of the yield-stress matrix bath have been characterized as well. A thick tissue-like structure with embedded single-layered, hollow channels has been successfully printed for demonstration. Since it is feasible to design coaxial nozzles with a core–shell–shell architecture, the proposed method is technically extendable to create double-layered channels within a cellular tissue construct, accurately mimicking human blood vascular networks in thick tissues in the future.

Smart hinges fabricated using three-dimensional (3D) printing have been accepted in the aerospace, robotics, and biomedical fields since these devices possess a shape memory characteristic. Shape memory polymers (SMPs) are the preferred materials for creating smart hinges due to their ability to achieve programmable complex geometries. However, fabricating SMPs with embedded components remains a challenge due to the constraints of current 3D printing methods and material limitations. This study investigated the use of a hybrid 3D printing method, direct ink writing (DIW), and embedded 3D printing (e-3DP) to print smart hinges with an embedded circuit to act as a strain sensor. The main components of the SMP included tert-Butyl acrylate (tBA) and aliphatic urethane diacrylate (AUD), but this SMP ink had a low viscosity and could not be used for DIW or e-3DP. Fumed silica (FS) was added to the SMP to tune its rheology, and it was shown that the FS concentration significantly affected the rheological properties, dry-out process, filament geometries, and self-supporting capabilities. This study presents a hybrid 3D printing approach for creating smart hinges with internal strain sensors in one step, demonstrating the versatility of DIW/e-3DP. The findings from this work provide a foundational and reliable technical solution to efficiently fabricate functional, self-monitoring, smart devices from SMPs for diverse applications.

Microfluidic devices made from polydimethylsiloxane (PDMS) have diverse biomedical applications. However, due to the poor printability of PDMS, current 3D printing techniques are rarely used to fabricate microfluidic devices. This study aims to investigate a fumed silica-PDMS suspension that can function as a matrix bath for embedded 3D printing (e-3DP) purposes, making it technically feasible to print microfluidic chips with complex embedded channels via low-cost extrusion 3D printing. The rheological properties, mechanical properties, transparency, and filament fidelity of the fumed silica-PDMS suspension have been systematically studied. It is found that the addition of fumed silica particles can effectively change PDMS from a viscous solution to a yield-stress suspension with suitable rheological properties for e-3DP. Also, the mechanical properties of the crosslinked fumed silica-PDMS are enhanced with an increased concentration of fumed silica. Although the transparency of PDMS has been lessened by mixing it with fumed silica particles, the visibility of the printed microfluidic chips is still acceptable. The filament fidelity has been studied by embedded printing filaments using a sacrificial ink in the fumed silica-PDMS suspension. Finally, two representative microfluidic chips for biomedical applications have been successfully printed to validate the effectiveness of the proposed fumed silica-PDMS suspension-enabled e-3DP method.

Polymeric parts have been increasingly used in various engineering fields. The performance of polymeric parts is significantly affected by working-environment-induced aging. In this paper, an ultrasonic-vibration-assisted injection molding system was designed and utilized to fabricate polymeric parts from isotactic polypropylene (iPP) using different processing conditions. The natural aging experiments were performed to age the fabricated iPP parts for one year. The effects of key process parameters as well as ultrasound power on the microstructures and the mechanical properties of the iPP parts after aging were systematically investigated using X-ray diffraction analysis, Fourier transform infrared analysis, scanning electron microscope imaging, and tensile testing. It is found that both the microstructures and the tensile strength of the iPP parts deteriorate with the increasing aging time. In addition, the crystallinity and the tensile strength decrease with the increasing melt temperature but increase with the increasing mold temperature in a given range and holding pressure. The increase in ultrasound power leads to an increase in crystallinity. However, when the ultrasound power is over 200 W, the tensile strength of the aged iPP parts decreases, which indicates that high ultrasound power may not form optimal condensed microstructures with excellent anti-aging capacity.