The capability to print three-dimensional (3D) cellular tubes is not only a logical first step towards successful organ printing but also a critical indicator of the feasibility of the envisioned organ printing technology. A platform-assisted 3D inkjet bioprinting system has been proposed to fabricate 3D complex constructs such as zigzag tubes. Fibroblast (3T3 cell)-based tubes with an overhang structure have been successfully fabricated using the proposed bioprinting system. The post-printing 3T3 cell viability of printed cellular tubes has been found above 82% (or 93% with the control effect considered) even after a 72-h incubation period using the identified printing conditions for good droplet formation, indicating the promising application of the proposed bioprinting system. Particularly, it is proved that the tubular overhang structure can be scaffold-free fabricated using inkjetting, and the maximum achievable height depends on the inclination angle of the overhang structure. As a proof-of-concept study, the resulting fabrication knowledge helps print tissue-engineered blood vessels with complex geometry.

Organ printing offers a great potential for the freeform layer-by-layer fabrication of three-dimensional (3D) living organs using cellular spheroids or bioinks as building blocks. Vascularization is often identified as a main technological barrier for building 3D organs. As such, the fabrication of 3D biological vascular trees is of great importance for the overall feasibility of the envisioned organ printing approach. In this study, vascular-like cellular structures are fabricated using a liquid support-based inkjet printing approach, which utilizes a calcium chloride solution as both a cross-linking agent and support material. This solution enables the freeform printing of spanning and overhang features by providing a buoyant force. A heuristic approach is implemented to compensate for the axially-varying deformation of horizontal tubular structures to achieve a uniform diameter along their axial directions. Vascular-like structures with both horizontal and vertical bifurcations have been successfully printed from sodium alginate only as well as mouse fibroblast-based alginate bioinks. The post-printing fibroblast cell viability of printed cellular tubes was found to be above 90% even after a 24 h incubation, considering the control effect.

Biofabrication offers a great potential for the fabrication of three-dimensional living tissues and organs by precisely layer-by-layer placing various tissue spheroids as anatomically designed. Inkjet printing of living cell-laden bioink is one of the most promising technologies enabling biofabrication, and the bioink printability must be carefully examined for it to be a viable biofabrication technology. In this study, the cell-laden bioink droplet formation process has been studied in terms of the breakup time, droplet size and velocity, and satellite formation using a time-resolved imaging approach. The bioink has been prepared using fibroblasts and sodium alginate with four different cell concentrations: without cells, 1 × 10(6), 5 × 10(6), and 1 × 10(7) cells/mL to appreciate the effect of cell concentration on the droplet formation process. Furthermore, the bioink droplet formation process is compared with that during the inkjetting of a comparable polystyrene microbead-laden suspension under the identical operating conditions to understand the effect of particle physical properties on the droplet formation process. It is found that (1) as the cell concentration of bioink increases, the droplet size and velocity decrease, the formation of satellite droplets is suppressed, and the breakup time increases, and (2) compared to the hard bead-laden suspension, the bioink tends to have a less ejected fluid volume, lower droplet velocity, and longer breakup time.

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Three-dimensional (3D) bioprinting, as a freeform biomedical manufacturing approach, has been increasingly adopted for the fabrication of constructs analogous to living tissues. Generally, materials printed during 3D bioprinting are referred as bioinks, which may include living cells, extracellular matrix materials, cell media, and/or other additives. For 3D bioprinting to be an enabling tissue engineering approach, the bioink printability is a critical requirement as tissue constructs must be able to be printed and reproduce the complex micro-architecture of native tissues in vitro in sufficient resolution. The bioink printability is generally characterized in terms of the controllable formation of well-defined droplets/jets/filaments and/or the morphology and shape fidelity of deposited building blocks. This review presents a comprehensive overview of the studies of bioink printability during representative 3D bioprinting processes, including inkjet printing, laser printing, and micro-extrusion, with a focus on the understanding of the underlying physics during the formation of bioink-based features. A detailed discussion is conducted based on the typical time scales and dimensionless quantities for printability evaluation during bioprinting. For inkjet printing, the Z (the inverse of the Ohnesorge number), Weber, and capillary numbers have been employed for the construction of phase diagrams during the printing of Newtonian fluids, while the Weissenberg and Deborah numbers have been utilized during the printing of non-Newtonian bioinks. During laser printing of Newtonian solutions, the jettability can be characterized using the inverse of the Ohnesorge number, while Ohnesorge, elasto-capillary, and Weber numbers have been utilized to construct phase diagrams for typical non-Newtonian bioinks. For micro-extrusion, seven filament types have been identified including three types of well-defined filaments and four types of irregular filaments. During micro-extrusion, the Oldroyd number has been used to characterize the dimensions of the yielded areas of Herschel-Bulkley fluids. Non-ideal jetting behaviors are common during the droplet-based inkjet and laser printing processes due to the local nonuniformity and nonhomogeneity of cell-laden bioinks.

Metallic aerogels have attracted intense attention due to their superior properties, such as high electrical conductivity, ultralow densities, and large specific surface area. The preparation of metal aerogels with high efficiency and controllability remains challenge. A 3D freeze assembling printing technique integrated with drop-on-demand inkjet printing and freeze casting are proposed for metallic aerogels preparation. This technique enables tailoring both the macrostructure and microstructure of silver nanowire aerogels (SNWAs) by integrating programmable 3D printing and freeze casting, respectively. The density of the printed SNWAs is controllable, which can be down to 1.3 mg cm . The ultralight SNWAs reach high electrical conductivity of 1.3 S cm and exhibit excellent compressive resilience under 50% compressive strain. Remarkably, the printing methodology also enables tuning aerogel architectures with designed Poisson's ratio (from negative to positive). Moreover, these aerogel architechtures with tunable Poisson's ratio present highly electromechanical stability under high compressive and tensile strain (both strain up to 20% with fully recovery).

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Photocrosslinkable polymers such as gelatin methacrylate (GelMA) have various 3D bioprinting applications. These polymers crosslink upon exposure to UV irradiation with the existence of an appropriate photoinitiator. Two photoinitiators, Irgacure 2959 and lithium phenyl-2,4,6-trimethylbenzoylphosphinate (LAP) are commonly used. This study systematically investigates the effects of photoinitiator types on the cell viability, physical properties, and microstructure in 3D bioprinting of GelMA-based cellular constructs. The main conclusions are: (1) during the 3D bioprinting, the cell viability generally decreases as the photoinitiator concentration and printing time increase using both Irgacure 2959 and LAP. At the low photoinitiator concentrations (such as 0.3% and 0.5% (w/v)), the overall cell viability is good within the printing time of 60 min using both Irgacure 2959 and LAP. However, at the high photoinitiator concentrations (such as 0.7% and 0.9% (w/v)), the overall cell viability using LAP is much higher than that using Irgacure 2959 within the printing time of 60 min; (2) after the 3D bioprinting, the photoinitiator types, either Irgacure 2959 or LAP, have negligible effects on the post-printing cell viability after crosslinking; (3) after the 3D bioprinting, GelMA samples cured with Irgacure 2959 have slightly larger pore size, faster degradation rate, and greater swelling ratio compared to those cured with LAP; (4) 3D GelMA-based vascular-like constructs have been fabricated using dynamic optical projection stereolithography, and the measured dimensions have been compared with the designed dimensions showing good shape fidelity.