Layered Fabrication of Branched Networks Using Lindenmayer Systems

A current challenge impeding the growth of bone tissue engineering is the lack of functional scaffolds of geometric sizes greater than 10mm due to the inability of cells to survive deep within the scaffold. It is hypothesized that these scaffolds must have an inbuilt nutrient distribution network to sustain the uniform growth of cells. In this paper, we seek to enhance the design and layered fabrication of scaffold internal architecture through the development of Lindenmayer systems, a graphical language based theory to create nutrient delivery networks. The scaffolds are fabricated using the Texas Instruments DLP™ system through UV‐photopolymerization to produce polyethylene glycol hydrogels with internal branch structures. The paper will discuss the Lindenmayer system, process planning algorithms, layered fabrication of samples, challenges and future tasks.Mechanical Engineerin

Optofluidic fabrication for 3D-shaped particles.

Complex three-dimensional (3D)-shaped particles could play unique roles in biotechnology, structural mechanics and self-assembly. Current methods of fabricating 3D-shaped particles such as 3D printing, injection moulding or photolithography are limited because of low-resolution, low-throughput or complicated/expensive procedures. Here, we present a novel method called optofluidic fabrication for the generation of complex 3D-shaped polymer particles based on two coupled processes: inertial flow shaping and ultraviolet (UV) light polymerization. Pillars within fluidic platforms are used to deterministically deform photosensitive precursor fluid streams. The channels are then illuminated with patterned UV light to polymerize the photosensitive fluid, creating particles with multi-scale 3D geometries. The fundamental advantages of optofluidic fabrication include high-resolution, multi-scalability, dynamic tunability, simple operation and great potential for bulk fabrication with full automation. Through different combinations of pillar configurations, flow rates and UV light patterns, an infinite set of 3D-shaped particles is available, and a variety are demonstrated

UV-Photolithography Fabrication of Poly-Ethylene Glycol Hydrogels Encapsulated with Hepatocytes

The development of biomanufacturing technologies particularly, layered manufacturing has advanced cell encapsulation processes in an effort to mimic the cellular microenvironment for invitro studies. This paper illustrates an inexpensive UV-photolithographic method for encapsulation of human hepatocytes in three dimensional structures using poly-ethylene diacrylate (PEGDA) hydrogels as candidate substrates. In order to further develop this technology for layered fabrication, we have quantified the long-term effects of the photo-initiator concentration and UV light exposure on the metabolic rates of encapsulated human hepatocytes under a 21 day study. The photoinitator toxicity was observed immediately after polymerization with no significant cytotoxicity on a long term basis. A cellular viability is examined and reported for the UV photopolymerization process. Cell phenotype maintenance was observed by measuring the amount of urea produced over a 1 week time period. This photo encapsulation process may find use in the fabrication of spatially complex 3D scaffolds for tissue engineering applications, elucidation of the 3D structure-pharmacokinetic response relationship and the fabrication of complex multi-compartment liver tissue analog devices for drug screening applications.Mechanical Engineerin

Development of a 3D printer using scanning projection stereolithography

We have developed a system for the rapid fabrication of low cost 3D devices and systems in the laboratory with micro-scale features yet cm-scale objects. Our system is inspired by maskless lithography, where a digital micromirror device (DMD) is used to project patterns with resolution up to 10 µm onto a layer of photoresist. Large area objects can be fabricated by stitching projected images over a 5cm2 area. The addition of a z-stage allows multiple layers to be stacked to create 3D objects, removing the need for any developing or etching steps but at the same time leading to true 3D devices which are robust, configurable and scalable. We demonstrate the applications of the system by printing a range of micro-scale objects as well as a fully functioning microfluidic droplet device and test its integrity by pumping dye through the channels