Combining 3D Printing with Electrospinning for Rapid Response and Enhanced Designability of Hydrogel Actuators

Porous structures have emerged as a breakthrough of shape‐morphing hydrogels to achieve a rapid response. However, these porous actuators generally suffer from a lack of complexity and diversity in obtained 3D shapes. Herein, a simple yet versatile strategy is developed to generate shape‐morphing hydrogels with both fast deformation and enhanced designability in 3D shapes by combining two promising technologies: electrospinning and 3D printing. Elaborate patterns are printed on mesostructured stimuli‐responsive electrospun membranes, modulating in‐plane and interlayer internal stresses induced by swelling/shrinkage mismatch, and thus guiding morphing behaviors of electrospun membranes to adapt to changes of the environment. With this strategy, a series of fast deformed hydrogel actuators are constructed with various distinctive responsive behaviors, including reversible/irreversible formations of 3D structures, folding of 3D tubes, and formations of 3D structures with multi low‐energy states. It is worth noting that although poly(N‐isopropyl acrylamide) is chosen as the model system in the present research, our strategy is applicable to other stimuli‐responsive hydrogels, which enriches designs of rapid deformed hydrogel actuators.     

4D Printing of Hydrogels: A Review

3D printing permits the construction of objects by layer‐by‐layer deposition of material, resulting in precise control of the dimensions and properties of complex printed structures. Although 3D printing fabricates inanimate objects, the emerging technology of 4D printing allows for animated structures that change their shape, function, or properties over time when exposed to specific external stimuli after fabrication. Among the materials used in 4D printing, hydrogels have attracted growing interest due to the availability of various smart hydrogels. The reversible shape‐morphing in 4D printed hydrogel structures is driven by a stress mismatch arising from the different swelling degrees in the parts of the structure upon application of a stimulus. This review provides the state‐of‐the‐art of 4D printing of hydrogels from the materials perspective. First, the main 3D printing technologies employed are briefly depicted, and, for each one, the required physico‐chemical properties of the precursor material. Then, the hydrogels that have been printed are described, including stimuli‐responsive hydrogels, non‐responsive hydrogels that are sensitive to solvent absorption/desorption, and multimaterial structures that are totally hydrogel‐based. Finally, the current and future applications of this technology are presented, and the requisites and avenues of improvement in terms of material properties are discussed.     

Photocurable 3D Printing of High Toughness and Self-Healing Hydrogels for Customized Wearable Flexible Sensors

Currently, most customized hydrogels can only be processed via extrusion-based 3D printing techniques, which is limited by printing efficiency and resolution. Here, a simple strategy for the rapid fabrication of customized hydrogels using a photocurable 3D printing technique is presented. This technique has been rarely used because the presence of water increases the molecular distance between the polymer chains and reduces the monomer polymerization rate, resulting in the failure of rapid solid-liquid separation during printing. Although adding cross-linkers to printing inks can effectively accelerate 3D cross-linked network formation, chemical cross-linking may result in reduced toughness and self-healing ability of the hydrogel. Therefore, an interpenetrated-network hydrogel based on non-covalent interactions is designed to form physical cross-links, affording fast solid-liquid separation. Poly(acrylic acid (AA)-N-vinyl-2-pyrrolidone (NVP)) and carboxymethyl cellulose (CMC) are cross-linked via Zn²⁺-ligand coordination and hydrogen bonding; the resulting mixed AA-NVP/CMC solution is used as the printing ink. The printed poly(AA-NVP/CMC) hydrogel exhibited high tensile toughness (3.38 MJ m⁻³) and superior self-healing ability (healed stress: 81%; healed strain: 91%). Some objects like manipulator are successfully customized by photocurable 3D printing using hydrogels with high toughness and complex structures. This high-performance hydrogel has great potential for application in flexible wearable sensors.     

3D Printing of Multifunctional Hydrogels

3D printing technology has been widely explored for the rapid design and fabrication of hydrogels, as required by complicated soft structures and devices. Here, a new 3D printing method is presented based on the rheology modifier of Carbomer for direct ink writing of various functional hydrogels. Carbomer is shown to be highly efficient in providing ideal rheological behaviors for multifunctional hydrogel inks, including double network hydrogels, magnetic hydrogels, temperature‐sensitive hydrogels, and biogels, with a low dosage (at least 0.5% w/v) recorded. Besides the excellent printing performance, mechanical behaviors, and biocompatibility, the 3D printed multifunctional hydrogels enable various soft devices, including loadable webs, soft robots, 4D printed leaves, and hydrogel Petri dishes. Moreover, with its unprecedented capability, the Carbomer‐based 3D printing method opens new avenues for bioprinting manufacturing and integrated hydrogel devices.     

Biodegradable,Sustainable Hydrogel Actuators with Shape and Stiffness Morphing Capabilities via Embedded 3D Printing

Despite the impressive performance of recent marine robots, many of their components are non-biodegradable or even toxic and may negatively impact sensitive ecosystems. To overcome these limitations, biologically-sourced hydrogels are a candidate material for marine robotics. Recent advances in embedded 3D printing have expanded the design freedom of hydrogel additive manufacturing. However, 3D printing small-scale hydrogel-based actuators remains challenging. In this study, Free form reversible embedding of suspended hydrogels (FRESH) printing is applied to fabricate small-scale biologically-derived, marine-sourced hydraulic actuators by printing thin-wall structures that are water-tight and pressurizable. Calcium-alginate hydrogels are used, a sustainable biomaterial sourced from brown seaweed. This process allows actuators to have complex shapes and internal cavities that are difficult to achieve with traditional fabrication techniques. Furthermore, it demonstrates that fabricated components are biodegradable, safely edible, and digestible by marine organisms. Finally, a reversible chelation-crosslinking mechanism is implemented to dynamically modify alginate actuators' structural stiffness and morphology. This study expands the possible design space for biodegradable marine robots by improving the manufacturability of complex soft devices using biologically-sourced materials.     

A Self-Thickening and Self-Strengthening Strategy for 3D Printing High-Strength and Antiswelling Supramolecular Polymer Hydrogels as Meniscus Substitutes

3D printing of high-strength and antiswelling hydrogel-based load-bearing soft tissue scaffolds with similar geometric shape to natural tissues remains a great challenge owing to insurmountable trade-off between strength and printability. Herein, capitalizing on the concentration-dependent H-bonding-strengthened mechanism of supramolecular poly(N-acryloyl glycinamide) (PNAGA) hydrogel, a self-thickening and self-strengthening strategy, that is, loading the concentrated NAGA monomer into the thermoreversible low-strength PNAGA hydrogel is proposed to directly 3D printing latently H-bonding-reinforced hydrogels. The low-strength PNAGA serves to thicken the concentrated NAGA monomer, affording an appropriate viscosity for thermal-assisted extrusion 3D printing of soft PNAGA hydrogels bearing NAGA monomer and initiator, which are further polymerized to eventually generate high-strength and antiswelling hydrogels, due to the reconstruction of strong H-bonding interactions from postcompensatory PNAGA. Diverse polymer hydrogels can be printed with self-thickened corresponding monomer inks. Further, the self-thickened high-strength PNAGA hydrogel is printed into a meniscus, which is implanted in rabbit's knee as a substitute with in vivo outcome showing an appealing ability to efficiently alleviate the cartilage surface wear. The self-thickening strategy is applicable to directly printing a variety of polymer-hydrogel-based tissue engineering scaffolds without sacrificing mechanical strength, thus circumventing problems of printing high-strength hydrogels and facilitating their application scope.     

Strong and Ultra-Tough Supramolecular Hydrogel Enabled by Strain-Induced Microphase Separation

Architected hydrogels are widely used in biomedicine, soft robots, and flexible electronics while still possess big challenges in strong toughness, and shape modeling. Here, inspired with the universal hydrogen bonding interactions in biological systems, a strain-induced microphase separation path toward achieving the printable, tough supramolecular polymer hydrogels by hydrogen bond engineering is developed. Specifically, it subtly designs and fabricates the poly (N-acryloylsemicarbazide-co-acrylic acid) hydrogels with high hydrogen bond energy by phase conversion induced hydrogen bond reconstruction. The resultant hydrogels exhibited the unique strain-induced microphase separation behavior, resulting in the excellent strong toughness with, for example, an ultimate stress of 9.1 ± 0.3 MPa, strain levels of 1020 ± 126%, toughness of 33.7 ± 6.6 MJ m⁻³, and fracture energy of 171.1 ± 34.3 kJ m⁻². More importantly, the hydrogen bond engineered supramolecular hydrogels possess dynamic shape memory character, i.e shape fixing at low temperature while recovery after heating. As the proof of concept, the tailored hydrogel stents are readily manufactured by 3D printing, which showed good biocompatibility, load-bearing and drug elution, being beneficial for the biomedical applications. It is believed that the present 3D printing of the architected dynamic hydrogels with ultrahigh toughness can broaden their applications.     

3D Printing of Hydrogels for Stretchable Ionotronic Devices

In the booming development of flexible electronics represented by electronic skins, soft robots, and human–machine interfaces, 3D printing of hydrogels, an approach used by the biofabrication community, is drawing attention from researchers working on hydrogel-based stretchable ionotronic devices. Such devices can greatly benefit from the excellent patterning capability of 3D printing in three dimensions, as well as the free design complexity and easy upscale potential. Compared to the advanced stage of 3D bioprinting, 3D printing of hydrogel ionotronic devices is in its infancy due to the difficulty in balancing printability, ionic conductivity, shape fidelity, stretchability, and other functionalities. In this review, a guideline is provided on how to utilize the power of 3D printing in building high-performance hydrogel-based stretchable ionotronic devices mainly from a materials’ point of view, highlighting the systematic approach to balancing the printability, printing quality, and performance of printed devices. Various 3D printing methods for hydrogels are introduced, and then the ink design principles, balancing printing quality, printed functions, such as elastic conductivity, self-healing ability, and device (e.g., flexible sensors, shape-morphing actuators, soft robots, electroluminescent devices, and electrochemical biosensors) performances are discussed. In conclusion, perspectives on the future directions of this exciting field are presented.     

Fabrication of Thermoresponsive Hydrogel Scaffolds with Engineered Microscale Vasculatures

Precise fabrication of microscale vasculatures (MSVs) has long been an unresolved challenge in tissue engineering. Currently, light-assisted printing is the most common approach. However, this approach is often associated with an intricate fabrication process, high cost, and a requirement for specific photoresponsive materials. Here, thermoresponsive hydrogels are employed to induce volume shrinkage at 37 °C, which allows for MSV engineering without complex protocols. The thermoresponsive hydrogel consists of thermosensitive poly(N-isopropylacrylamide) and biocompatible gelatin methacrylate (GelMA). In cell culture, the thermoresponsive hydrogel exhibits an apparent volume shrinkage and effectively triggers the creation of MSVs with smaller size. The results show that a higher concentration of GelMA blocks the shrinkage, and the thermoresponsive hydrogel demonstrates different behaviors in water and air at 37 °C. The MSVs can be effectively fabricated using the sacrificial alginate fibers, and the minimum MSV diameter achieved is 50 µm. Human umbilical vein endothelial cells form endothelial monolayers in the MSVs. Osteosarcoma cells maintain high viability in the thermoresponsive hydrogel, and the in vivo experiment shows that the MSVs provide a site for the perfusion of host vessels. This technique may help in the development of a facile method for fabricating MSVs and demonstrates strong potential for clinical application in tissue regeneration.     

Fluidic Infiltrative Assembly of 3D Hydrogel with Heterogeneous Composition and Function

3D hydrogels are powerful, multifunctional materials that are poised to become a building block in next-generation systems. Modern schemes to print complex 3D hydrogels are advancing rapidly; however, they possess several limitations including—but not limited to—polymer incompatibility or difficulty in imparting continuous heterogeneity in composition or function. Here, a simple strategy of synthesizing programmable hydrogel systems with tunable form and function in 3D is presented. This approach utilizes commercially available stereolithographic printer/resin to fabricate high-resolution molds followed by the programmed infiltration and gelation of hydrogel prepolymer. This mold is then sacrificed to yield 3D, multifunctional hydrogels exhibiting user-defined heterogeneity. The approach is compatible with numerous in-situ gelling polymers and modifiers ranging from interpenetrating networks of organic or synthetic polymers to functional materials possessing dense concentrations of nanomaterials or fluorescent markers. Accessible and versatile, this approach allows the fabrication of complex, multimaterial constructs with tunable 3D environmental responses inaccessible to well-established hydrogel 3D printing methods.     

3D Printing of Resilin in Water by Multiphoton Absorption Polymerization

Resilin is an elastic rubber-like protein found in the cuticles of insects. It incorporates outstanding properties of high resilience and fatigue lifetime, where kinetic energy storage is needed for biological functions such as flight and jumps. Since resilin is rich in tyrosine groups, localized photopolymerization is enabled due to the ability to introduce di-tyrosine bonds by a ruthenium-based photoinitiator. Using Multiphoton Absorption Polymerization 3D printing process, objects containing 100% recombinant resilin protein are printed in water at a submicron length scale. Consequently, protein-based hydrogels with complex structures are printed using space positioning voxel polymerization. The objects are characterized by dynamic mechanical analysis using nanoindentation. Printing parameters such as printing speed and laser power are found to enable tuning the mechanical properties of the printed objects. The printed objects are soft and resilient, similar to native resilin, while presenting the highest resolution of a structure made entirely of a protein and better mechanical properties of common hydrogels and poly(dimethylsiloxane). Moreover, topography and mechanical properties enable cell growth and alignment without cell adhesion primers, thus facilitating biological applications. The fabrication of 3D resilin-based hydrogel will open the way for potential applications based on biomimicking and in creating new functional objects.     

3D Printing of Multifunctional Conductive Polymer Composite Hydrogels

Functional conductive hydrogels are widely used in various application scenarios, such as artificial skin, cell scaffolds, and implantable bioelectronics. However, their novel designs and technological innovations are severely hampered by traditional manufacturing approaches. Direct ink writing (DIW) is considered a viable industrial-production 3D-printing technology for the custom production of hydrogels according to the intended applications. Unfortunately, creating functional conductive hydrogels by DIW has long been plagued by complicated ink formulation and printing processes. In this study, a highly 3D printable poly(3,4-ethylenedioxythiophene):polystyrene sulfonate (PEDOT:PSS)-based ink made from fully commercially accessible raw materials is demonstrated. It is shown that complex structures can be directly printed with this ink and then precisely converted into high-performance hydrogels via a post-printing freeze–thawing treatment. The 3D-printed hydrogel exhibits high electrical conductivity of ≈2000 S m⁻¹, outstanding elasticity, high stability and durability in water, electromagnetic interference shielding, and sensing capabilities. Moreover, the hydrogel is biocompatible, showing great potential for implantable and tissue engineering applications. With significant advantages, the fabrication strategy is expected to open up a new route to create multifunctional hydrogels with custom features, and can bring new opportunities to broaden the applications of hydrogel materials.     

Programmed Deformations of 3D‐Printed Tough Physical Hydrogels with High Response Speed and Large Output Force

Shape‐morphing hydrogels have emerging applications in biomedical devices, soft robotics, and so on. However, successful applications require a combination of excellent mechanical properties and fast responding speed, which are usually a trade‐off in hydrogel‐based devices. Here, a facile approach to fabricate 3D gel constructs by extrusion‐based printing of tough physical hydrogels, which show programmable deformations with high response speed and large output force, is described. Highly viscoelastic poly(acrylic acid‐co‐acrylamide) (P(AAc‐co‐AAm)) and poly(acrylic acid‐co‐N‐isopropyl acrylamide) (P(AAc‐co‐NIPAm)) solutions or their mixtures are printed into 3D constructs by using multiple nozzles, which are then transferred into FeCl₃ solution to gel the structures by forming robust carboxyl–Fe³⁺ coordination complexes. The printed gel fibers containing poly(N‐isopropyl acrylamide) segment exhibit considerable volume contraction in concentrated saline solution, whereas the P(AAc‐co‐AAm) ones do not contract. The mismatch in responsiveness of the gel fibers affords the integrated 3D gel constructs the shape‐morphing ability. Because of the small diameter of gel fibers, the printed gel structures deform and recover with a fast speed. A four‐armed gripper is designed to clamp plastic balls with considerable holding force, as large as 115 times the weight of the gripper. This strategy should be applicable to other tough hydrogels and broaden their applications.     

Self-Shaping Soft Electronics Based on Patterned Hydrogel with Stencil-Printed Liquid Metal

Hydrogel-based soft electronics (HSE) is promising as implantable devices due to the similarity of hydrogel substrates to biologic tissues. Most existing HSE devices are based on conducting hydrogels that usually have weak mechanical properties, low conductivity, and poor patternability. Reported here is an HSE with good mechanical performance, high sensitivity, and versatile functions by stencil printing of liquid metal on a tough hydrogel, facilitating integration of multiple sensing units. Self-shaping ability is imparted to the HSE by creating gradient structure in the hydrogel substrate. The resultant HSE actively deforms into 3D configurations with zero or nonzero Gaussian curvature to fix on objects or organs with sophisticated geometries and maintains the sensing functions. The versatilities and potential applications of this HSE are demonstrated by monitoring motions of a rice field eel and beatings of a rabbit heart. Such HSE based on morphing substrate should pave the way for implantable electronics with better fixation and interfacial contact with the organs. The concept of morphing hydrogel devices can be extended to other soft electronics with responsive polymer films or elastomers as the substrates.     

4D Printing of Multi-Stimuli Responsive Protein-Based Hydrogels for Autonomous Shape Transformations

Stimuli responsive hydrogels that can change shape in response to applied external stimuli are appealing for soft robotics, biomedical devices, drug delivery, and actuators. However, existing 3D printed shape morphing materials are non-biodegradable, which limits their use in biomedical applications. Here, 3D printed protein-based hydrogels are developed and applied for programmable structural changes under the action of temperature, pH, or an enzyme. Key to the success of this strategy is the use of methacrylated bovine serum albumin (MA–BSA) as a biodegradable building block to Pickering emulsion gels in the presence of N-isopropylacrylamide or 2-dimethylaminoethyl methacrylate. These shear-thinning gels are ideal for direct ink write (DIW) 3D printing of multi-layered stimuli-responsive hydrogels. While poly(N-isopropylacrylamide) and poly(dimethylaminoethyl methacrylate) introduce temperature and pH-responsive properties into the printed objects, a unique feature of this strategy is an enzyme-triggered shape transformation based on the degradation of the bovine serum albumin network. To highlight this technique, protein-based hydrogels that reversibly change shape based on environmental temperature and pH are fabricated, and irreversibly altered by enzymatic degradation, which demonstrates the complexity that can be introduced into 4D printed systems.     

Surface Patterning of Hydrogels for Programmable and Complex Shape Deformations by Ion Inkjet Printing

Convenient patterning and precisely programmable shape deformations are crucial for the practical applications of shape deformable hydrogels. Here, a facile and versatile computer‐assisted ion inkjet printing technique is described that enables the direct printing of batched, very complicated patterns, especially those with well‐defined, programmable variation in cross‐linking densities, on one or both surfaces of a large‐sized hydrogel sample. A mechanically strong hydrogel containing poly(sodium acrylate) is first prepared, and then digital patterns are printed onto the hydrogel surfaces by using a commercial inkjet printer and an aqueous ferric solution. The complexation between the polyelectrolyte and ferric ions increases the cross‐linking density of the printed regions, and hence the gel sample can undergo shape deformation upon swelling/deswelling. The deformation rates and degrees of the hydrogels can be conveniently adjusted by changing the printing times or the different/gradient grayscale distribution of designed patterns. By printing appropriate patterns on one or both surfaces of the hydrogel sheets, many complex 3D shapes are obtained from shape deformations upon swelling/deswelling, such as cylindrical shell and forsythia flower (patterns on one surface), ding (patterns on both surfaces), blooming flower (different/gradient grayscale distributive patterns on one surface), and non‐Euclidean plates (different/gradient grayscale distributive patterns on both surfaces).     

3D Printing of Bioinspired Alginate-Albumin Based Instant Gel Ink with Electroconductivity and Its Expansion to Direct Four-Axis Printing of Hollow Porous Tubular Constructs without Supporting Materials

A successful 3D printable hydrogel ink needs not only biofunctionalities but also minimal fabrication steps such as multiple crosslinking sites, high printability, cytocompatibility, high shape fidelity, stability, shear thinning, robust properties, and less time-consuming processing steps, by maximizing known material chemistries and functionalities. This work reports a novel bioinspired conjugate with polysaccharide (alginate)–tannic acid (TA)–protein (bovine serum albumin) to fabricate proteoglycan-like gels, which are 3D printable with multilayers, shear-thinning, elastic, electroconductive (with carbon nanotubes), controlled crosslinking/degradation through multiple crosslinking mechanisms (TA, Ca²⁺ ions, and NaIO₄ oxidation), and interactions with cytocompatible hydrogel system. The synthesis process is simple, and gelation (within 2 h) is ensured without any chemical crosslinking agents (at room temperature). While cell-adhesive albumin largely improves cytocompatibility, carbon nanotubes in the gel give electrical conductivity in the different four-axis 3D printed structures, including large hollow tubular constructs. This work demonstrates promising results of electroconductive proteoglycan-like gel ink to address the challenges in 3D/four-axis ink printing such as synthesis, printability, shape fidelity, electroconductivity, controlled fabrication and degradation, cytocompatibility, and multiple crosslinking abilities to maintain the dimensions of the diversely printed constructs.     

Inherent Photodegradability of Polymethacrylate Hydrogels: Straightforward Access to Biocompatible Soft Microstructures

Hydrogels are important functional materials useful for 3D cell culture, tissue engineering, 3D printing, drug delivery, sensors, or soft robotics. The ability to shape hydrogels into defined 3D structures, patterns, or particles is crucial for biomedical applications. Here, the rapid photodegradability of commonly used polymethacrylate hydrogels is demonstrated without the need to incorporate additional photolabile functionalities. Hydrogel degradation depths are quantified with respect to the irradiation time, light intensity, and chemical composition. It can be shown that these parameters can be utilized to control the photodegradation behavior of polymethacrylate hydrogels. The photodegradation kinetics, the change in mechanical properties of polymethacrylate hydrogels upon UV irradiation, as well as the photodegradation products are investigated. This approach is then exploited for microstructuring and patterning of hydrogels including hydrogel gradients as well as for the formation of hydrogel particles and hydrogel arrays of well‐defined shapes. Cell repellent but biocompatible hydrogel microwells are fabricated using this method and used to form arrays of cell spheroids. As this method is based on readily available and commonly used methacrylates and can be conducted using cheap UV light sources, it has vast potential to be applied by laboratories with various backgrounds and for diverse applications.     

Printing Reconfigurable Bundles of Dielectric Elastomer Fibers

Active soft materials that change shape on demand are of interest for a myriad of applications, including soft robotics, biomedical devices, and adaptive systems. Despite recent advances, the ability to rapidly design and fabricate active matter in complex, reconfigurable layouts remains challenging. Here, the 3D printing of core-sheath-shell dielectric elastomer fibers (DEF) and fiber bundles with programmable actuation is reported. Complex shape morphing responses are achieved by printing individually addressable fibers within 3D architectures, including vertical coils and fiber bundles. These DEF devices exhibit resonance frequencies up to 700 Hz and lifetimes exceeding 2.6 million cycles. The multimaterial, multicore-shell 3D printing method opens new avenues for creating active soft matter with fast programable actuation.     

Engineering Tridimensional Hydrogel Tissue and Organ Phantoms with Tunable Springiness

Biomimicking organ phantoms with vivid biological structures and soft and slippery features are essential for in vitro biomedical applications yet remain hither to unmet challenges in their fabrication such as balancing between spatial structural complexity and matchable mechanical properties. Herein, 3D printable tissue-mimicking elastomeric double network hydrogels with tailorable stiffness are evolved to idiosyncratically match diverse biological soft tissues by regulating the compositions of hydrogel matrix and the density of metal coordination bonds. Relying on digital light processing 3D printing, various mechanically tunable biomimetic volumetric hydrogel organ constructs with structural complexity and fidelity, including kidney, brain, heart, liver, stomach, lung, trachea, intestine, and even the intricate vascularized tissues, are fabricated faultlessly. Proof-of-concept 3D printed hydrogel heart and liver phantoms provide sophisticated internal channels and cavity structures and external realistic anatomical architectures that more closely mimic native organs. For the in vitro application demonstration, a 3D printed hydrogel brain phantom with tortuous cerebral arteries and slippery characters serves as an effective neurosurgical training platform for realistic simulation of endovascular interventions. This platform offers a means to construct mechanically precisely tunable hydrogel-based biomimetic organ phantoms that are expected to be used in surgical training, medical device testing, and organs-on-chips.