Additive manufacturing of ultrahigh-resolution Poly(ε-caprolactone) scaffolds using melt electrowriting

Abstract

Melt electrowriting (MEW) is an advanced additive manufacturing technology that produces high-resolution scaffolds for medical applications. Although there are many valuable parameter groups for MEW, the corresponding principles need to be clarified to improve the success of printing high-fidelity scaffolds. To this end, we investigate the print limit of MEW with respect to the minimum interfiber distance and the maximum print period based on a medical-grade poly(ε-caprolactone) material. The results indicate that relatively large turning loops and low turning speeds improve the print accuracy of the scaffolds; however, excessively large turning loops and low turning speeds result in fiber accumulation on the edge of the scaffolds, resulting in print failure. The turning loops with 500 μm in diameter and turning speeds of 0.625 × CTS (critical translation speed) can achieve well-defined MEW scaffolds with an interfiber distance down to 25 μm. For printing such high-resolution scaffolds, the constant printing process can last one week. Fiber placement gets random when the fiber diameter is larger than 2.5 μm, caused by the melt polymer degradation and shear thinning in the printing process. Additionally, we verify that the method of charge neutralization is not beneficial for improving the fiber overlay. This is a fundamental study clarifying the principles of printing high-resolution MEW scaffolds, being capable of extending the application of the MEW products.