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com Current Opinion in

ScienceDirect Biomedical Engineering

3D bioprinting from the micrometer to millimeter


length scales: Size does matter
T. J. Hintona,1, Andrew Leea,1 and Adam W. Feinberga,b

3D bioprinting has rapidly expanded from a niche technology enables precision layer-by-layer material deposition in 3
and in to a versatile platform for fabricating tissues with com- dimensions (Figure 1a). The cost of these systems has
plex geometries and features ranging from the cellular to organ decreased significantly, driven by open-source hardware
length scales. Recent advances include the development of and software technologies that have enabled develop-
yield-stress support baths that enable soft hydrogels to be 3D ment of new bioprinting approaches and spurred broader
printed in highly complex structures and vascular networks and adoption through custom-built and lower-cost com-
successful implantation of 3D printed scaffolds in animal mercial printers [1e3]. Equally important is the ability
models and human patients towards regenerating bone, to use patient-specific 3D medical imaging data from
cartilage and muscle. However, the range of additive MRI and CT, providing the potential to repair regions of
manufacturing technologies currently used each has distinct damaged or diseased tissues, and perhaps eventually
advantages and disadvantages, and specifically it is critical to whole organs [4].
understand how the resolution of these different approaches
dictate structure and function of the engineered tissue con- Herein, we describe recent advances in 3D bioprinting,
structs. This article offers a focused review on how the size of with a focus on how the physical size (resolution) of the
the biomaterial that is being deposited or polymerized, which material being deposited dictates the performance
can range over 4 orders-of-magnitude from ~1 mm up to 1 mm, and properties of the scaffolds being fabricated,
drives biological performance. and ultimately the functionality of the engineered
tissues. This is important because 3D bioprinting en-
compasses multiple underlying technologies that achieve
Addresses
a
Department of Biomedical Engineering, Carnegie Mellon University,
additive manufacturing (AM) through extrusion, photo-
Pittsburgh, PA, USA polymerization, melting and/or jetting. Resolution can
b
Department of Materials Science and Engineering, Carnegie Mellon range from w1 mm diameter for extruded filaments down
University, Pittsburgh, PA, USA to <1 mm diameter photopolymerized voxels, with each
approach and material used representing a trade off in
Corresponding author: Feinberg, Adam W (feinberg@andrew.cmu.edu)
1
Denotes equal contribution.
resolution, print time, and cell viability (Figure 1b, c).
Researchers have now demonstrated this across a broad
range of applications from large-volume constructs for
Current Opinion in Biomedical Engineering 2017, 1:31–37 tissue repair to microvascular networks for improved cell
This review comes from a themed issue on Future of BME viability. It is clear that size does matter, with distinct
Edited by George Truskey
advantages and disadvantages for scaffolds fabricated at
the micrometer, mesoscopic and millimeter length scales.
Received 16 December 2016, revised 7 February 2017, accepted 13
February 2017
How these factors interrelate is critical to understanding
current and future advances in 3D bioprinting.

http://dx.doi.org/10.1016/j.cobme.2017.02.004
3D bioprinting with millimeter-scale
2468-4511/© 2017 Published by Elsevier Inc.
features for large-volume scaffolds
3D bioprinting has emerged as a viable strategy for
Abbreviations fabricating large-volume constructs with anatomically-
FDM, fused deposition modeling; SLS, selective laser sintering; AM, accurate structure. The goal for constructs printed at
additive manufacturing; MRI, magnetic resonance imaging; CT,
computed tomography; FRESH, Freeform Reversible Embedding of
this scale are to one day be transplantable into humans
Suspended Hydrogels; DLP, digital light processing; PCL, poly- to replace diseased tissues and organs. To this end, the
caprolactone; PEKK, polyetherketoneketone.: additive manufacturing approaches that have achieved
the most clinically-relevant results in 3D bioprinting
Introduction are extrusion-based deposition and laser-based tech-
Over the past decade, 3D bioprinting has rapidly nologies that have already had decades of use with
evolved from a niche research area and into a main- industrial-grade plastics. For example, both extrusion-
stream biofabrication platform. Core to this shift is the based deposition of thermoplastics, commonly known
robotic-controlled, additive manufacturing process that as fused deposition modeling (FDM), and laser-based
fusion of thermoplastic powders, commonly known as
selective laser sintering (SLS), are mature 3D printing

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32 Future of BME

Figure 1

(a) Schematic of a 3D bioprinter consisting of a 3-axis robot with one or more fluid extruders. (b) Extrusion nozzles vary in diameter orders of magnitude
from approximately 10 mm–1 mm, and focused laser light to a sub-micron spot size smaller than a cell. (c) For comparison, living tissue such as skeletal
muscle possesses hierarchical organization that spans several orders of magnitude from the macro-to microscopic scale.

technologies that have transitioned into 3D bioprinting depositing a range of hydrogels using syringe-based ex-
by using biocompatible polymers. These approaches truders that function similar to FDM, but avoid the
have an effective resolution of approximately 400 mm to thermal heating that can damage cells and biological
1 mm depending on the orifice diameter of the ther- molecules. For example, Manoor et al. 3D printed an ear
moplastic extruder in FDM or the powder diameter and using a cell-laden alginate hydrogel bioink that could
laser spot size for SLS. While this results in limited receive auditory signals via its embedded conductive coils
control of material microstructure, it provides distinct (Figure 2d) [7], essentially creating a biohybrid device.
advantages in fabricating large constructs >1 cm3 in Using a similar approach, Rhee et al. 3D printed a cell-
volume, and as a result has been the primary approach laden collagen ink in the shape of the meniscus cartilage
used for in vivo studies. For example, SLS 3D printing of and found that the construct was mechanically stable with
polyetherketoneketone (PEKK) is used for its high tunable compressive strength (Figure 2e) [8]. However,
strength in the load-bearing function of a 3D printed the resolution of hydrogels 3D printed in air is limited by
cranial plate for human skull reconstruction surgeries the deformability of these materials. In order to create
[5]. This demonstrates that 3D bioprinting of non- constructs that could better maintain geometry and be
resorbable, medical-grade polymers can produce FDA- implanted in vivo, multi-extruder setups were used by
approved, high-performance medical devices that can both Kang et al. and Daly et al. to sequentially deposit a
integrate with patient-specific anatomy. The future of PCL thermoplastic alongside a stem-cell laden hydrogel
3D bioprinting lies in extending this to biodegradable ink to create bone-like constructs [9,10]. When implanted
materials that can support true tissue regeneration. For subcutaneously, the PCL served as a structural support,
example, Zopf et al. SLS printed a tracheal splint from and the hydrogel components were found to be osteoin-
polycaprolactone (PCL) to support ventilation in a pe- ductive throughout the millimeter-scale constructs.
diatric patient with respiratory failure, utilizing the Hung et al. showed that PCL can be further modified with
relatively high stiffness material to prevent tracheal decellularized bone matrix particles to facilitate improved
collapse and a porous design for flexibility during bone regeneration in a temporomandibular joint construct
respiration (Figure 2aec) [6]. The PCL is a biode- (Figure 2f, g) [11]. Tissue-specific maturation strategies
gradable thermoplastic, and depending on formulation, can also be incorporated into printed constructs based on
can be tuned to degrade over a period of months to years print geometry. Kang et al. also combined cell-laden
to match the rate of tissue regeneration. These exam- hydrogel ink, PCL and Pluronic F-127 as a sacrificial ma-
ples serve to demonstrate the feasibility of adapting terial to temporarily support parallel extrusions of a
traditional 3D printing technologies for creating rigid hydrogel-myoblast mixture, facilitating myoblast align-
constructs with structurally functional millimeter-scale ment and fusion in culture (Figure 2h, i) [9]. When
features. implanted for 2 weeks in a mouse model, the construct
showed a degree of neural and vascular integration. These
For 3D bioprinting soft tissue, recent advances have studies add to a growing body of research that shows the
focused on incorporating cells and soft biomaterials such feasibility of macroscale bioprinting for fabricating large
as hydrogels and evaluating performance in more complex anatomically-accurate constructs, and the potential for
in vitro and in vivo environments. This has largely involved in vivo applications.

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3D bioprinting from the micrometer to millimeter Hinton et al. 33

Figure 2

(a) Minimum intensity projection of the respiratory airway from a CT scan is used to (b) 3D print a tracheal splint (red box) and its intended placement
location on a similarly printed model of the airway. (c) The splint is placed and sutured over the softened region of the left mainstem bronchial segment
[6]. (d) Bioprinting of a bionic ear with a chondrocyte-seeded alginate hydrogel and silver nanoparticle infused conductive coil [7]. (e) 3D printed
meniscus from collagen I hydrogel [8]. (f) The temporomandibular joint of the jaw (circled) is (g) bioprinted with varying percentage of decellularized
mineral particles [11]. (h) Muscle fiber bundle design is (i) printed with a sacrificial material Pluronic F-127 for temporary support of a myoblast-laden
hydrogel [9].

3D bioprinting at the millimeter scale has achieved 3D bioprinting at the mesoscale to control
important advances in fabricating organ-like constructs hierarchical architecture
that can be implanted into animal models and human Within tissue engineering, the mesoscale bridges the
patients. However, higher resolution features are macro- and microscopic domains and thus provides the
necessary for recapitulating structure and ultimately ability to define specific hierarchical architectures [15].
function of native tissues. While these features can be Branching vascular networks are key mesoscale features
achieved with the use of a smaller extruder orifice or important for providing nutrient supply in thick, tissue
finer laser focus, smaller extrusion diameters lead engineered constructs, but they have traditionally been
directly to a larger number of machine movements, difficult to construct. Recent technological advances
which results in longer print times. For example, an have uniquely positioned 3D bioprinting as a feasible
organ-scale construct can take 2e10 h to print, which is strategy for fabricating these structures at physiologically-
problematic because cell viability will decrease and cells relevant resolutions.
can settle out of suspension and alter uniformity of the
bioink [12,13]. Although increasing print speeds can 3D printed sacrificial (i.e., fugitive) materials that can
reduce print times of these large-scale constructs, high be removed later have proven to be highly effective for
speed and high precision movement systems are chal- predefining void regions within a bulk gel for micro-
lenging to implement. Biomaterials must also be vascular networks. For example, multiple groups have
developed specifically for printability, which is dictated printed sacrificial materials such as thermosensitive
by material rheology and gelation mechanism, while also Pluronic F-127 ink or water-soluble carbohydrate glass,
maintaining tissue-specific biochemical and mechanical casted an ECM gel around the printed structure, and
properties in the printed construct. While Pati et al. removed the sacrificial material to produce mesoscale
have shown that it is possible to create organ-derived vascular-like structures [16e19]. This approach allows
extracellular matrix (ECM) inks from animal tissues, fabrication of intricate 3D void networks that resemble
immunogenicity of these inks as well as material abun- key physiological structures that are otherwise difficult
dance are major hurdles when scaling towards human- to manufacture, such as a thick vascularized tissue
sized constructs [14]. Until we can interface large (Figure 3a, b), a convoluted renal proximal tubule model
organotypic structures with higher resolution features at (Figure 3c, d) [17,18] and a vascular lattice network
the meso- and microscale without loss of cell viability, (Figure 3eeg) [19]. Instead of patterning the void re-
macroscopic printed constructs will be able to reproduce gions of a construct with a sacrificial material, Itoh et al.
the tissue geometry but be limited in terms of tissue- defined the 3D position of cell spheroids w400 mm in
specific function. diameter by immobilizing them on an array of metal

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34 Future of BME

Figure 3

(a) A vascularized tissue fabrication process that casts an ECM hydrogel around printed paths of a sacrificial ink, which can be evacuated and perfused
to create (b) a thick multicellular tissue with endothelialized vascular network [17]. A similar technique is used to produce a (c) renal proximal tubule
model with (d) a dense cellular monolayer with native-like morphological features such as the cilia and functional epithelial marker Na+/K+ ATPase [18].
(e) Schematic and (f) perfusion time-lapse of vascular channels fabricated from fugitive carbohydrate glass [19]. (g) An array of metal needles used to
spatially position pre-formed cell spheroids in 3D to create (h) a compacted, cellularized tubular structure [20]. (i) Freeform embedded printing into
thermoreversible support to form (j) single alginate hydrogel strand, (k) a perfusable vascular tree network, and (l) a 3D printed heart from an embryonic
chick heart model [23]. (m) Embedded printing of a (m) fluorescent microsphere suspension and (n) polyvinyl alcohol into a granular gel medium to
create complex 3D structures [24].

needles (Figure 3g, h) [20]. Over time the cell spheroids incorporate a sacrificial component, to deposit soft
fuse into an integrated tissue, with resolution limited by hydrogels at high resolution.
spheroid diameter and the void space generated by
spheroid separation. These approaches demonstrate the 3D bioprinting of soft hydrogels within a support bath can
importance of patterning void space in 3D, but do not achieve mesoscale material deposition to build complex
address the mesoscale printing of hydrogels directly. scaffolds that would deform if unsupported. Using a
Inkjet is another 3D bioprinting technology that can method termed Freeform Reversible Embedding of
deposit hydrogels and cell directly in a drop-wise Suspended Hydrogels (FRESH), Hinton et al. showed
fashion. Recent work has demonstrated the 3D print- that a hydrogel precursor solution could be deposited and
ing of silk fibroin using a sacrificial alginate support [21] gelled within a thermoreversible support bath composed
and collagen combined with thermo-responsive agarose of a gelatin microparticulate slurry (Figure 3i, j) [23].
for bone tissue engineering applications [22]. While an Complex 3D prints of alginate, fibrin, Matrigel, and
important approach, inkjet mesoscale printing requires a collagen were achieved, including a perfusable model of a
support material, or special ink formulations that human right coronary artery tree from MRI (Figure 3k)

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3D bioprinting from the micrometer to millimeter Hinton et al. 35

and an embryonic-stage, trabeculated chick heart from biological function and complexity. As 3D printers evolve,
multiphoton imaging (Figure 3l) [23]. Unique to the these systems will begin operating with advanced motion
FRESH process is complete melting of the support bath control, microliter extrusion precision, and increased
at a physiologic 37  C, and bioprinted sheets of cells in resolution, which combined with metrological validation,
collagen-Matrigel hydrogels showed viability greater than will improve the output of mesoscale bioprinting.
97% [23]. Bhattacharjee et al. reported a similar approach
using a slurry (granular medium) of carbomer microgels as
3D bioprinting at the microscale to engineer
a support bath for a variety of UV-curable inks with
the cellular environment
embedded cells [24] and even the direct 3D printing of
It is now recognized that the structure of the ECM on the
cells alone [25]. Complex 3D prints were fabricated from
subcellular level influences cell behavior and tissue or-
fluorescent inks embedded into the support bath,
ganization. However, using extrusion to 3D bioprint
including a 3D tube with a complicated knot geometry
tissue microarchitecture is challenging because it re-
(Figure 3m) and a jellyfish inspired print with intricate
quires handling small volumes of non-Newtonian
arms (Figure 3n) [24]. These embedded printing ap-
biopolymer fluids. For this reason, digital light process-
proaches have expanded the complexity of 3D bioprinted
ing (DLP) and multiphoton laser scanning have emerged
scaffolds from hydrogels, but there are challenges to
as 3D bioprinting platforms for photocrosslinking bio-
depositing one material within a second material. For
materials and building scaffolds with spatial resolutions of
example, the granular support bath can influence the
<10 mm. For example, Ma et al. have demonstrated that
morphology of the deposited material and the thermo-
DLP printing and visible-light photo-initiators can be
reversible microparticles can also leave void space
used to develop constructs of multiple cell types and
within the print once removed [3,23]. Future studies will
materials at a scale consistent with that of the human liver
need to evaluate how cells will respond to this surface
lobule (Figure 4a, b) [26]. Claeyssens et al.utilized
topography or how this porosity will affect long term cell
multiphoton excitation to print PCL-based scaffolds with
culture of printed scaffolds.
4 mm features, and Zhang et al. were able to pattern
PEGDA into 1 mm spheres and filaments [27,28]. Arrays
Maturing printed tissues in culture will require consid-
of filament-like polymerized resin created by Ma et al.
eration of nutrient transport and cell-driven compaction
were able to align contractile cardiomyocytes (Figure 4c,
as part of printed tissue design; moreover, printing pa-
d, e) [29]. The multiphoton effect can also be used to
rameters such as infill patterning or spacing between
selectively stiffen a gel (Figure 4f) or spatially pattern
perimeter extrusions may be critical for achieving desired
molecules at specific locations in 3D (Figure 4g) [30,31].
properties. Merging the multiple process parameters of
These optical printing methods not only create micro-
extrusion-based 3D printing with a better understanding
scopic hydrogel geometries, but also demonstrate the
of engineered tissue design has the potential for improved

Figure 4

(a) Digital light processing (DLP) engines with individually addressed pixels can render complex patterns of illumination onto a variety of substrates, and
(b) patterned photopolymerization can selectively isolate different cell types in separate gels [26]. (c) Multiphoton photopolymerization can be used to
scan a small excitation point through a medium creating (d) rods of polymer that can support (e) cultures of aligned cardiomyocytes [29]. (f) Hollow
structures fabricated via multiphoton photopolymerization [30]. (g) Fluorescent image of separate growth factor molecules (red and green) photo-
immobilized by multiphoton photopolymerization within a 3D hydrogel [31].

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36 Future of BME

ability to spatially pattern molecular concentration and performance standard based on rendering of surface detail
matrix stiffness within these gels. and overhanging geometric features. Open-source bio-
printing, such as that utilized by Miller et al. and Hinton
Light-based techniques achieve high resolution but need et al., rely on the efforts of the RepRap movement (http://
to address the settling of cells out of photopolymer sus- reprap.org), including software capable of generating the
pensions, phototoxicity from repeated irradiation, and the toolpaths (G-code) used by the majority of desktop 3D
time required to prepare each new layer for exposure to printers [19,23,33]. These low-cost printers are built on
light. For example, in DLP and similar projection-based open-source frameworks where improvements can be
methods, liquid prepolymer must be added to build the shared to benefit the community. The accessibility of
next layer, which takes a relatively long time compared to these 3D bioprinting platforms should encourage wider
the duration of exposure and can produce shearing forces adoption and foster further innovation. This should also
on cells. Similarly, as print time increases exponentially lead to standardized 3D metrology for assessing material
with higher resolution, cell viability decreases due to time and printer performance, which will be required to tran-
in suspension and outside of standard culture conditions. sition 3D bioprinting into a clinically relevant bio-
Continuous Light Interface Printing (CLIP) and other fabrication platform.
light-based continuous exposure printing methods may
offer hope for faster, higher resolution bioprinting, but the Acknowledgements
chemistry is not currently biocompatible [32]. Scaling This research did not receive any specific grant from funding agencies in
the public, commercial, or not-for-profit sectors.
high-resolution microscopic techniques up toward the
macroscopic requires extremely precise hardware and the
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