Hierarchical porous materials made by stereolithographic printing of photo-curable emulsions

Kleger, Nicole; Minas, Clara; Bosshard, Patrick; Mattich, Iacopo; Masania, Kunal; Studart, André R.

doi:10.1038/s41598-021-01720-6

Cited by 32 publications

(8 citation statements)

References 40 publications

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“…In this method, 3D printing makes the macropores and the emulsion droplets and the pore throats form the micropores. [219][220][221][222][223][224] For example, nanoHA/PCL composite scaffolds have been prepared by 3D printing of HIPEs. To achieve this, a dichloromethane solution containing PCL with dispersed HA and silica nanoparticles was transformed into a water-in-oil HIPE by slowly adding water.…”

Section: Gas Foaming and Sinteringmentioning

confidence: 99%

Glass, Ceramic, Polymeric, and Composite Scaffolds with Multiscale Porosity for Bone Tissue Engineering

Jeyachandran

Cerruti

2023

Adv Eng Mater

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Porosity affects performance of scaffolds for bone tissue engineering both in vitro and in vivo. Macropores (i.e., pores with a diameter >100 μm) are essential for cellular infiltration; micropores (i.e., pores with a diameter of 1–10 μm) promote cell adhesion and facilitate nutrient absorption. Scaffolds containing both macropores and micropores exploit the advantages of both pore sizes and have excellent osteogenic properties. Nanopores (i.e., pores with a diameter of 1–50 nm) can be included as well, to improve cell–material interactions by further enhancing the surface area of the scaffold. This article reviews fabrication techniques and properties of scaffolds with multiscale porosity, focusing on glass, ceramic, polymeric, and composite scaffolds. After discussing the structure of bone and how it inspired scaffolds for bone tissue engineering, pore nomenclature is introduced. Then, the techniques used to induce multiscale porosity, the nature of the pores created, and the effects of scaffold porosity on mechanical properties and biological activity of the scaffolds are discussed. The review concludes by providing an outlook for this field, including advancements that are made possible by computational modeling and artificial intelligence.

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Section: Gas Foaming and Sinteringmentioning

confidence: 99%

Glass, Ceramic, Polymeric, and Composite Scaffolds with Multiscale Porosity for Bone Tissue Engineering

Jeyachandran

Cerruti

2023

Adv Eng Mater

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“…There is growing interest in using additive manufacturing methods to produce geometrically complex ceramics [1,2] for myriad applications, including catalyst supports, [3,4] battery electrodes, [5,6] heat exchangers, [7] and bone scaffolds, [8][9][10][11][12] among others. Currently, stereolithography [13][14][15][16][17][18][19] (SLA) and direct ink writing [20][21][22][23][24][25] (DIW) are the most widely used methods for printing ceramic structures. Ceramic-based SLA relies on the photopolymerization of preceramic polymers [17,26] or particleladen resins.…”

Section: Introductionmentioning

confidence: 99%

Embedded 3D Printing of Architected Ceramics via Microwave‐Activated Polymerization

et al. 2023

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polymers, [31,32] and foams [33][34][35] in a layerwise manner. To date, DIW has been used to produce periodic ceramic architectures ranging from honeycombs to 3D woodpile lattices. However, despite significant advances in both light-and ink-based 3DP methods, freeform fabrication of ceramic architectures with arbitrary composition and geometry remains challenging.Embedded 3D (EMB3D) printing offers a promising route for creating architected ceramics via freeform writing in a support matrix. In its initial embodiment, vascularized systems were produced by writing sacrificial inks within soft [36,37] and living [38] matrices. This method was extended to create soft strain sensors and proprioceptive robotic grippers by writing conductive particle-filled [39] and ionogel inks [40] within elastomeric matrices, respectively. More recently, other research groups have generated ceramic filaments by printing colloidal inks within a sacrificial support matrix. [41,42] However, they did not create complex structures nor report their microstructural or mechanical properties after densification. Hence, the ability to dry, cure, and harvest ceramic parts produced by EMB3D printing for load-bearing applications has yet to be demonstrated.Here, we report a method for fabricating architected ceramics with controlled composition in arbitrary geometries that combines EMB3D printing with microwave-activated curing. [43,44] We first created concentrated colloidal gels that contain thermally curable species and are compatible with our silicone-based support matrix while exhibiting the requisite rheological properties for EMB3D printing. As exemplars, we printed architected ceramics in the form of monolithic and multimaterial lattices, as well as interpenetrating chain structures. Next, we investigated the effects of microwave-activated curing on the ability to generate parts with sufficient handling strength for their removal from the support matrix and subsequent densification during sintering. Our integrated manufacturing approach enables complex ceramics architectures to be manufactured with programmable composition in freeform shapes that may be of potential interest for structural, biomedical, and energy applications. Results and DiscussionEMB3D printing with microwave-activated curing is shown in Figure 1a. Printed filaments are extruded through a nozzle Light-and ink-based 3D printing methods have vastly expanded the design space and geometric complexity of architected ceramics. However, light-based methods are typically confined to a relatively narrow range of preceramic and particle-laden resins, while ink-based methods are limited in geometric complexity due to layerwise assembly. Here, embedded 3D printing is combined with microwave-activated curing to generate architected ceramics with spatially controlled composition in freeform shapes. Aqueous colloidal inks are printed within a support matrix, rapidly cured via microwave-activated polymerization, and subsequently dried and sintered into dense architectures composed of ...

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“…However, the direct relationships between the photocurable formulations, usually based on acrylates, and the properties of these carbons, especially the mechanical properties, have not been studied thus far, and only general trends have been observed (i.e., the increase of the properties with density [ 8 ] or the effect of anisotropy due to the printing technology [ 9 ]). To this end, it is essential to understand the effects of the various components of the resin formulation on the final properties of the carbons.…”

Section: Introductionmentioning

confidence: 99%

Experimental Design Optimization of Acrylate—Tannin Photocurable Resins for 3D Printing of Bio-Based Porous Carbon Architectures

et al. 2022

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In this work, porous carbons were prepared by 3D printing formulations based on acrylate–tannin resins. As the properties of these carbons are highly dependent on the composition of the precursor, it is essential to understand this effect to optimise them for a given application. Thus, experimental design was applied, for the first time, to carbon 3D printing. Using a rationalised number of experiments suggested by a Scheffé mixture design, the experimental responses (the carbon yield, compressive strength, and Young’s modulus) were modelled and predicted as a function of the relative proportions of the three main resin ingredients (HDDA, PETA, and CN154CG). The results revealed that formulations containing a low proportion of HDDA and moderate amounts of PETA and CN154CG gave the best properties. Thereby, the optimised carbon structures had a compressive strength of over 5.2 MPa and a Young’s modulus of about 215 MPa. The reliability of the model was successfully validated through optimisation tests, proving the value of experimental design in developing customisable tannin-based porous carbons manufactured by stereolithography.

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Hierarchical porous materials made by stereolithographic printing of photo-curable emulsions

Cited by 32 publications

References 40 publications

Glass, Ceramic, Polymeric, and Composite Scaffolds with Multiscale Porosity for Bone Tissue Engineering

Glass, Ceramic, Polymeric, and Composite Scaffolds with Multiscale Porosity for Bone Tissue Engineering

Embedded 3D Printing of Architected Ceramics via Microwave‐Activated Polymerization

Experimental Design Optimization of Acrylate—Tannin Photocurable Resins for 3D Printing of Bio-Based Porous Carbon Architectures

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