A review on powder-based additive manufacturing for tissue engineering: selective laser sintering and inkjet 3D printing

Abstract

Since most starting materials for tissue engineering are in powder form, using powder-based additive manufacturing methods is attractive and practical. The principal point of employing additive manufacturing (AM) systems is to fabricate parts with arbitrary geometrical complexity with relatively minimal tooling cost and time. Selective laser sintering (SLS) and inkjet 3D printing (3DP) are two powerful and versatile AM techniques which are applicable to powder-based material systems. Hence, the latest state of knowledge available on the use of AM powder-based techniques in tissue engineering and their effect on mechanical and biological properties of fabricated tissues and scaffolds must be updated. Determining the effective setup of parameters, developing improved biocompatible/bioactive materials, and improving the mechanical/biological properties of laser sintered and 3D printed tissues are the three main concerns which have been investigated in this article.     

A review on powder-based additive manufacturing for tissue engineering: selective laser sintering and inkjet 3D printing

Since most starting materials for tissue engineering are in powder form, using powder-based additive manufacturing methods is attractive and practical. The principal point of employing additive manufacturing (AM) systems is to fabricate parts with arbitrary geometrical complexity with relatively minimal tooling cost and time. Selective laser sintering (SLS) and inkjet 3D printing (3DP) are two powerful and versatile AM techniques which are applicable to powder-based material systems. Hence, the latest state of knowledge available on the use of AM powder-based techniques in tissue engineering and their effect on mechanical and biological properties of fabricated tissues and scaffolds must be updated. Determining the effective setup of parameters, developing improved biocompatible/bioactive materials, and improving the mechanical/biological properties of laser sintered and 3D printed tissues are the three main concerns which have been investigated in this article.     

Biomanufacturing for tissue engineering: Present and future trends

Tissue engineering, often referred to as regenerative medicine and reparative medicine, is an interdisciplinary field that necessitates the combined effort of cell biologists, engineers, material scientists, mathematicians, geneticists, and clinicians toward the development of biological substitutes that restore, maintain, or improve tissue function. It has emerged as a rapidly expanding approach to address the organ shortage problem and comprises tissue regeneration and organ substitution. Cells placed on/or within constructs is the most common strategy in tissue engineering. Successful cell seeding depends on fast attachment of cell to scaffolds, high cell survival and uniform cell distribution. The seeding time is strongly dependent on the scaffold material and architecture. Scaffolds provide an initial biochemical substrate for the novel tissue until cells can produce their own extra-cellular matrix (ECM). Thus scaffolds not only define the 3D space for the formation of new tissues, but also serve to provide tissues with appropriate functions. These scaffolds are often critical, both in vivo (within the body) or in vitro (outside the body) mimicking in vivo conditions. Additive fabrication processes represent a new group of non-conventional fabrication techniques recently introduced in the biomedical engineering field. In tissue engineering, additive fabrication processes have been used to produce scaffolds with customised external shape and predefined internal morphology, allowing good control of pore size and pore distribution. This article provides a comprehensive state-of-the-art review of the application of biomanufacturing additive processes in the field of tissue engineering. New and moving trends in biomanufacturing technologies and the concept of direct cell-printing technologies are also discussed.     

Bioactive collagen-grafted poly-L-lactic acid nanofibrous membrane for cartilage tissue engineering

Biodegradable nanofibrous membrane was prepared from poly-L-lactic acid by electrospinning and used as a scaffold for cartilage tissue engineering. Operating parameters during the electrospinning process were studied in terms of their influences on fiber diameter, membrane porosity and pore size. In order to improve cell attachment and growth, nanofibrous membrane was subject to DC-pulsed oxygen plasma treatment, followed by acrylic acid grafting and collagen coating by covalent binding of collagen to carboxylic moieties of the polyacrylic acid. The membrane was fully characterized for its physical and chemical properties. Primary chondrocyte cells seeded into the membrane proliferated well and maintain high viability within the membrane from Confocal Laser Scanning Microscopy. Cell differentiation was confirmed by secretion of glycoaminoglycan and collagen during the cultivation period. Scanning electron microscope observation of the cell-scaffold construct confirms the tight attachment of cells to nanofibers and in-growth of cells into the interior of the membrane with proper maintenance of morphology and structure of chondrocytes.     

Innovative tissue engineering structures through advanced manufacturing technologies

Awide range of rapid prototyping (RP) techniques for the construction of three-dimensional (3-D) scaffolds for tissue engineering has been recently developed. In this study, we report and compare two methods for the fabrication of poly-(epsilon-caprolactone) and poly-(epsilon-caprolactone)-poly-(oxyethylene)-poly-(epsilon-caprolactone) copolymer scaffolds. The first technique is based on the use of a microsyringe and a computer-controlled three-axis micropositioner, which regulates motor speed and position. Polymer solutions are extruded through the needle of the microsyringe by the application of a constant pressure of 10-300 mm Hg, resulting in controlled polymer deposition of 5-600 microm lateral dimensions. The second method utilises the heating energy of a laser beam to sinter polymer microparticles according to computer-guided geometries. Materials may be fed either as dry powder or slurry of microparticles. Both powder granulometry and laser working parameters influence resolution (generally 300 microm x 700 microm), accuracy of sintering and surface and bulk properties of the final structures. The two RP methods allow the fabrication of 3-D scaffolds with a controlled architecture, providing a powerful means to study cell response to an environment similar to that found     

Dual growth factor-releasing nanoparticle/hydrogel system for cartilage tissue engineering

In order to induce the chondrogenesis of mesenchymal stem cells (MSCs) in tissue engineering, a variety of growth factors have been adapted and encouraging results have been demonstrated. In this study, we developed a delivery system for dual growth factors using a gelation rate controllable alginate solution (containing BMP-7) and polyion complex nanoparticles (containing TGF-β₂) to be applied for the chondrogenesis of MSCs. The dual growth factors (BMP-7/TGF-β₂)-loaded nanoparticle/hydrogel system showed a controlled release of both growth factors: a faster release of BMP-7 and a slower release of TGF-β₂, ca., approximately 80 and 30% release at the end of an incubation period (21 days), respectively, which may be highly desirable for chondrogenic differentiation of MSCs. On the contrary, the release of each growth factor from the dual growth factors-loaded hydrogel (without the nanoparticles) was much slower than that of the nanoparticle/hydrogel system, approximately 36% (BMP-7) and 16% (TGF-β₂) for 21 days, and this is more than likely attributed to the aggregation between growth factors during the hydrogel fabrication step. The nanoparticle/hydrogel system with separate growth factor loading may provide desirable growth factor delivery kinetics for cartilage regeneration, as well as the chondrogenesis of MSCs.     

Evaluation of in vitro degradation of PCL scaffolds fabricated via BioExtrusion – Part 2: Influence of pore size and geometry

The in vivo degradation processes by which scaffolds degrade and are replaced by neo-tissue are complex and may be influenced by many factors, including environmental conditions, material properties, porosity and 3D architecture. The present study is focused on the influence of design parameters, filament distance (FD) and lay-down pattern, on the degradation kinetics of Polycaprolactone (PCL) scaffolds obtained via BioExtrusion. Through the variation of design parameters it was possible to obtain two groups of scaffolds with distinct pore geometry and size. The in vitro degradation was performed in simulated body fluid (SBF) and in phosphate buffer solution (PBS) for six months. Our results highlight a more complex degradation pattern of the scaffolds in SBF than in PBS, probably related to a mineral deposition. Significant statistical differences in weight loss values at month 6, allowed us to conclude that degradation kinetics of PCL scaffolds is strongly influenced by the pore size.     

A biomimetic three-dimensional woven composite scaffold for functional tissue engineering of cartilage

Tissue engineering seeks to repair or regenerate tissues through combinations of implanted cells, biomaterial scaffolds and biologically active molecules. The rapid restoration of tissue biomechanical function remains an important challenge, emphasizing the need to replicate structural and mechanical properties using novel scaffold designs. Here we present a microscale 3D weaving technique to generate anisotropic 3D woven structures as the basis for novel composite scaffolds that are consolidated with a chondrocyte-hydrogel mixture into cartilage tissue constructs. Composite scaffolds show mechanical properties of the same order of magnitude as values for native articular cartilage, as measured by compressive, tensile and shear testing. Moreover, our findings showed that porous composite scaffolds could be engineered with initial properties that reproduce the anisotropy, viscoelasticity and tension-compression nonlinearity of native articular cartilage. Such scaffolds uniquely combine the potential for load-bearing immediately after implantation in vivo with biological support for cell-based tissue regeneration without requiring cultivation in vitro.     

A 3D biodegradable protein based matrix for cartilage tissue engineering and stem cell differentiation to cartilage

A protein based 3D porous scaffold is fabricated by blending gelatin and albumin. The biomimetic biodegradable gelatin, promoted good cell adhesion and its hydrophilic nature enabled absorption of culture media. Albumin is proposed to serve as a nontoxic foaming agent and also helped to attain a hydrophobic-hydrophilic balance. The hydrophobic-hydrophilic balance and appropriate crosslinking of the scaffold avoided extensive swelling, as well as retained the stability of scaffold in culture medium for long period. The scaffold is found to be highly porous with open interconnected pores. The adequate swelling and mechanical property of the scaffold helped to withstand the loads imparted by the cells during in vitro culture. The scaffold served as a nontoxic material to monolayer of fibroblast cells and is found to be cell compatible. The suitability of scaffold for chondrocyte culture and stem cell differentiation to chondrocytes is further explored in this work. The scaffold provided appropriate environment for chondrocyte culture, resulting in deposition of cartilage specific matrix molecules that completely masked the pores of the porous scaffold. The scaffold promoted the proliferation and differentiation of mesenchymal stem cells to chondrocytes in presence of growth factors. The transforming growth factor, TGFbeta3 promoted better chondrogenic differentiation than its isoform TGFbeta1 in this scaffold.     

Glutaraldehyde and oxidised dextran as crosslinker reagents for chitosan-based scaffolds for cartilage tissue engineering

Chitosan crosslinked with glutaraldehyde or oxidised dextran was studied as a potential scaffold material in tissue engineering for cartilage regeneration. By mixing two solutions of both components it became a gel, which was frozen. After lyophilisation a scaffold was generated with interconnected pores with diameters ranging between 120–350 μm. The mechanical properties (yielding point, elastic and viscous moduli), absolute porosity, pore morphology were determined depending on the ratio of chitosan to crosslinker. ATDC5 (murine cell line) and bovine articular chondrocytes (primary cells) were cultured for 14 days on the scaffolds. Cultivation with ATDC5 cells and bovine chondrocytes showed no negative influence of glutaraldehyde on cell vitality and growth.     

Genipin-crosslinked gelatin scaffolds for articular cartilage tissue engineering with a novel crosslinking method

A novel crosslinking method with directly crosslinking the gelatin gel, being cut to a disc of chosen size beforehand, for the fabrication of porous gelatin scaffold was proposed. This novel method of gel-crosslinking was compared with the traditional methods of mixing-crosslinking and scaffold-crosslinking. The structure of the scaffold fabricated by the gel-crosslinking method shows uniformly distributed and interconnected pores which can be much smaller than those made by the other two methods. All three methods have the last step as freeze-drying; nevertheless, freeze-drying once more will increase the uniformity of the structure and the interconnecting pores. Crosslinking of gelatin was carried out at room temperature with glutaraldehyde (GTA) or genipin (GP). In vitro cell culture of Wistar rat's joint chondrocytes demonstrates that the GTA-crosslinked scaffold is much worse than the GP-crosslinked one; a tissue containing collagen and glycosaminoglycan was produced in the GP-crosslinked scaffold in just 9 days after cell seeding, and a tissue with a cell distribution resembling that of the native cartilage was developed after 30 day cell culture. It was concluded that the novel method is feasible for application in articular cartilage tissue engineering.     

A novel surface modification on calcium polyphosphate scaffold for articular cartilage tissue engineering

The surface of porous three-dimensional (3D) calcium polyphosphate (CPP) scaffold was modified by treatment of quenching-after-sintering in the fabrication process. Scanning electron microscopic examination and degradation tests confirmed a new type of surface modification. A rotary-shaking culture was compared to that of a stationary culture and the results showed that rotary shaking led to enhanced extracellular matrices (ECM) secretion of both proteoglycans and collagen. Rotary-shaking cultured results showed that the quenching-treated CPP scaffold produced a better cartilage tissue, with both proteoglycans and collagen secretions enhanced, than the air-cooled-after-sintering scaffolds. Moreover, β-CPP scaffolds were better for the ECM secretion of both proteoglycans and collagen than the β-CPP + γ-CPP multiphase scaffold. However, the multiphase scaffold led to higher growth rate than that of β-CPP scaffold; the quenching-after-sintering treatment reversed this. In addition, the ECM secretions of both proteoglycans and collagen in the quenching-treated β-CPP scaffold were higher than those in the air-cooled one. Thus, the novel treatment of quenching-after-sintering has shown merits to the porous 3D CPP scaffolds for articular cartilage tissue engineering.     

Chitosan particles agglomerated scaffolds for cartilage and osteochondral tissue engineering approaches with adipose tissue derived stem cells

In the XML file of the original article, H. Redl’s affiliation is incorrect. It is listed correctly in both the paper and PDF versions of the article, and can be found below: The online version of the original article can be found at     

Chitosan particles agglomerated scaffolds for cartilage and osteochondral tissue engineering approaches with adipose tissue derived stem cells

It is well accepted that natural tissue regeneration is unlikely to occur if the cells are not supplied with an extracellular matrix (ECM) substitute. With this goal, several different methodologies have been used to produce a variety of 3D scaffolds as artificial ECM substitutes suitable for bone and cartilage tissue engineering. Furthermore, osteochondral tissue engineering presents new challenges since the combination of scaffolding and co-culture requirements from both bone and cartilage applications is required in order to achieve a successful osteochondral construct. In this paper, an innovative processing route based on a chitosan particles aggregation methodology for the production of cartilage and osteochondral tissue engineering scaffolds is reported. An extensive characterization is presented including a morphological evaluation using Micro-Computed Tomography (μCT) and 3D virtual models built with an image processing software. Mechanical and water uptake characterizations were also carried out, evidencing the potential of the developed scaffolds for the proposed applications. Cytotoxicity tests show that the developed chitosan particles agglomerated scaffolds do not exert toxic effects on cells. Furthermore, osteochondral bilayered scaffolds could also be developed. Preliminary seeding of mesenchymal stem cells isolated from human adipose tissue was performed aiming at developing solutions for chondrogenic and osteogenic differentiation for osteochondral tissue engineering applications. An erratum to this article is available at .     

The importance of new processing techniques in tissue engineering

The use of polymer scaffolds in tissue engineering is reviewed and processing techniques are examined. The discussion of polymer-scaffold processing explains fiber bonding, solvent casting and particulate leaching, membrane lamination, melt molding, polymer/ceramic fiber composite-foam processing, phase separation, and high-pressure processing.     

Enhanced mechanical properties of thermosensitive chitosan hydrogel by silk fibers for cartilage tissue engineering

Articular cartilage has limited repair capability following traumatic injuries and current methods of treatment remain inefficient. Reconstructing cartilage provides a new way for cartilage repair and natural polymers are often used as scaffold because of their biocompatibility and biofunctionality. In this study, we added degummed chopped silk fibers and electrospun silk fibers to the thermosensitive chitosan/glycerophosphate hydrogels to reinforce two hydrogel constructs which were used as scaffold for hyaline cartilage regeneration. The gelation temperature and gelation time of hydrogel were analyzed by the rheometer and vial tilting method. Mechanical characterization was measured by uniaxial compression, indentation and dynamic mechanical analysis assay. Chondrocytes were then harvested from the knee joint of the New Zealand white rabbits and cultured in constructs. The cell proliferation, viability, production of glycosaminoglycans and collagen type II were assessed. The results showed that mechanical properties of the hydrogel were significantly enhanced when a hybrid with two layers of electrospun silk fibers was made. The results of GAG and collagen type II in cell-seeded scaffolds indicate support of the chondrogenic phenotype for chondrocytes with a significant increase in degummed silk fiber–hydrogel composite for GAG content and in two-layer electrospun fiber–hydrogel composite for Col II. It was concluded that these two modified scaffolds could be employed for cartilage tissue engineering.     

Microthermoforming as a novel technique for manufacturing scaffolds in tissue engineering (CellChips)

The CellChip is a microstructured polymer scaffold, which favours a three-dimensional cultivation of cells within an array of cubic microcontainers. The manufacturing process used so far is microinjection moulding combined with laser-based perforation. In a first attempt to simplify the process, costly perforation was avoided by using commercially available, inexpensive microfiltration membranes for the bottom of the microcavities. Microthermoforming is a promising novel technique which allows the CellChip to be produced from thin film. Working pressures of approximately 4000 kPa were required for the adequate moulding of 50 microm thick films from three different polymers (polystyrene, polycarbonate, cyclo-olefin polymer). Integrating drafts and chamfers in micromoulds is not going to eliminate an uneven thickness profile, but reduces demoulding forces. Microthermoformed CellChips of polycarbonate were perforated by an ion track technique to guarantee a sufficient supply of medium and gases to the cells. The prestructured CellChips were irradiated with 1460 MeV xenon ions at a fluence of a few 10(6) ions/cm2. The tracks were etched in an aqueous solution of 5 N NaOH at 30 degrees C, which resulted in cylindrical pores approximately 2 microm in diameter. Microinjection-moulded, membrane-bonded and thermoformed CellChips were subjected to comparative examination for viability in a cell culture experiment with parenchymal liver cells (HepG2). The cells stayed viable over a period of more than 20 days. No significant differences in viability between injection-moulded, membrane-bonded, and thermoformed CellChips were observed.     

Additive manufacturing process monitoring and control by non-destructive testing techniques: challenges and in-process monitoring

This paper examines on the obstacles specific to the implementation of non-destructive testing (NDT) techniques in additive manufacturing (AM). The general challenges impeding the adoption of AM for volume production of parts, and the use of NDT techniques to ameliorate some of these challenges are studied. These challenges include the lack of understanding of AM materials, and insufficient standards for the mechanical testing and NDT of additively manufactured parts. An overview on the principle of operation for in-process inspection NDT methods is presented. The techniques include thermography, and acoustic emission testing. The applications of these NDT techniques in AM and their suitability for defects detection of additively manufactured parts are reviewed. The sensitivity, and the advantages and disadvantages of each technique are evaluated. The types of defects, and the detectability of these defects by NDT techniques are assessed.