3D Microporous Scaffolds Manufactured via Combination of Fused Filament Fabrication and Direct Laser Writing Ablation

Mangirdas Malinauskas,Daiva Baltriukienė,Evaldas Balčiūnas,Arūnas Butkevičius,Laurynas Lukoševičius,Saulius Juodkazis,Vygandas Rutkūnas,Sima Rekštytė,Milda Pečiukaitytė,Simas Butkus,Virginija Bukelskienė,Povilas Kucevičius

doi:10.3390/mi5040839

Mangirdas Malinauskas, Daiva Baltriukienė + Show 10 more

Open Access

https://doi.org/10.3390/mi5040839

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Abstract

A 3D printing fused filament fabrication (FFF) approach has been implemented for the creation of microstructures having an internal 3D microstructure geometry. These objects were produced without any sacrificial structures or additional support materials, just by precisely tuning the nozzle heating, fan cooling and translation velocity parameters. The manufactured microporous structures out of polylactic acid (PLA) had fully controllable porosity (20%–60%) and consisted of desired volume pores (~0.056 μm3). The prepared scaffolds showed biocompatibility and were suitable for the primary stem cell growth. In addition, direct laser writing (DLW) ablation was employed to modify the surfaces of the PLA structures, drill holes, as well as shape the outer geometries of the created objects. The proposed combination of FFF printing with DLW offers successful fabrication of 3D microporous structures with functionalization capabilities, such as the modification of surfaces, the generation of grooves and microholes and cutting out precisely shaped structures (micro-arrows, micro-gears). The produced structures could serve as biomedical templates for cell culturing, as well as biodegradable implants for tissue engineering. The additional micro-architecture is important in connection with the cell types used for the intention of cell growing. Moreover, we show that surface roughness can be modified at the nanoscale by immersion into an acetone bath, thus increasing the hydrophilicity. The approach is not limited to biomedical applications, it could be employed for the manufacturing of bioresorbable 3D microfluidic and micromechanic structures.

Highlights

Additive manufacturing (AM) technologies are highly versatile and continuously growing in their width and depth of potential applications
We show the technology’s state-of-the-art and implemented extensions demonstrated in this study: the entire sequence of making large area and volume 3D microporous structures permeable for cell culture with engineered micro-patterns for directionality control of cell growth and controlled surface roughness for optimal cell adhesion, migration and proliferation
Further studies will be targeting the implementation of smaller diameter nozzles, decreasing the fused filament fabrication (FFF) producible feature dimensions

Summary

Introduction

Additive manufacturing (AM) technologies are highly versatile and continuously growing in their width and depth of potential applications. An immense ∼150% jump per year is seen for 3D printing based on thermal extrusion [2] This empowers the industrialization of various techniques from scientific laboratory equipment to batch production facilities. It presents the convenience of having a prototyping device for personal daily use at home. It is important to note that contrary to 2D objects, which are nothing more than just images carrying information, the 3D objects can offer real functions In this meaning, special attention should be given: a 2D object can serve as a label (instruction) for a 3D object, which could be the component performing some process. Before going deeper into details, an overview of existing technologies and processable materials will be presented stressing their advantages and limitations

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