3D bioprinting with high-viscosity solutions: A custom designed extrusion head for high-resolution cellulose acetate scaffolds

Additive manufacturing (AM) presents significant potential in the field of tissue engineering (TE), and in particular healing, replacing and regenerating damaged or diseased tissues. However, the high cost of commercially available bioprinters and the lack of suitably printed biomaterials has limited its widespread implementation and practical application in clinical settings. We present a novel approach where a cost-effective 3D bioprinter conversion kit was designed and fabricated using commercial 3D printers. Printing high-viscosity solutions is particularly challenging due to their resistance to flow and tendency to clog printing nozzles, yet the process was facilitated with the help of rheological characterization. By utilizing the properties of cellulose acetate (CA) as the chosen biomaterial, 3D bioprinting production of scaffolds was efficiently achieved without the need for curing or post-processing steps. Furthermore, a parametric troubleshooting procedure was developed to guide the optimization of printing parameters, clarify the behavior of the biomaterial, and improve the resolution of the 3D printed scaffold, as analyzed through Scanning electron microscope (SEM) imaging. Aim of this analysis; to obtain printing parameters tailored to the viscosity of the bioink and the evaporation characteristics of the organic solvent used in its formulation. Additionally, a series of preliminary cell culture studies were carried out to investigate the effect of these biophysical cues from the printed scaffolds on cells (e.g., adhesion, growth). This innovative and cost-effective solution has great potential to empower researchers in TE and support their exploration of advanced bioprinting techniques.