@article{MieszczanekRobinsonDaltonetal.2021, author = {Mieszczanek, Pawel and Robinson, Thomas M. and Dalton, Paul D. and Hutmacher, Dietmar W.}, title = {Convergence of Machine Vision and Melt Electrowriting}, series = {Advanced Materials}, volume = {33}, journal = {Advanced Materials}, number = {29}, doi = {10.1002/adma.202100519}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:20-opus-256365}, year = {2021}, abstract = {Melt electrowriting (MEW) is a high-resolution additive manufacturing technology that balances multiple parametric variables to arrive at a stable fabrication process. The better understanding of this balance is underscored here using high-resolution camera vision of jet stability profiles in different electrical fields. Complementing this visual information are fiber-diameter measurements obtained at precise points, allowing the correlation to electrified jet properties. Two process signatures—the jet angle and for the first time, the Taylor cone area—are monitored and analyzed with a machine vision system, while SEM imaging for diameter measurement correlates real-time information. This information, in turn, allows the detection and correction of fiber pulsing for accurate jet placement on the collector, and the in-process assessment of the fiber diameter. Improved process control is used to successfully fabricate collapsible MEW tubes; structures that require exceptional accuracy and printing stability. Using a precise winding angle of 60° and 300 layers, the resulting 12 mm-thick tubular structures have elastic snap-through instabilities associated with mechanical metamaterials. This study provides a detailed analysis of the fiber pulsing occurrence in MEW and highlights the importance of real-time monitoring of the Taylor cone volume to better understand, control, and predict printing instabilities.}, language = {en} } @article{LiashenkoHrynevichDalton2020, author = {Liashenko, Ievgenii and Hrynevich, Andrei and Dalton, Paul D.}, title = {Designing Outside the Box: Unlocking the Geometric Freedom of Melt Electrowriting using Microscale Layer Shifting}, series = {Advanced Materials}, volume = {32}, journal = {Advanced Materials}, number = {28}, doi = {10.1002/adma.202001874}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:20-opus-217974}, year = {2020}, abstract = {Melt electrowriting, a high-resolution additive manufacturing technology, has so far been developed with vertical stacking of fiber layers, with a printing trajectory that is constant for each layer. In this work, microscale layer shifting is introduced through deliberately offsetting the printing trajectory for each printed layer. Inaccuracies during the printing of sinusoidal walls are corrected via layer shifting, resulting in accurate control of their geometry and mechanical properties. Furthermore, more substantial layer shifting allows stacking of fiber layers in a horizontal manner, overcoming the electrostatic autofocusing effect that favors vertical layer stacking. Novel nonlinear geometries, such as overhangs, wall texturing and branching, and smooth and abrupt changes in printing trajectory are presented, demonstrating the flexibility of the layer shifting approach beyond the state-of-the-art. The practice of microscale layer shifting for melt electrowriting enables more complex geometries that promise to have a profound impact on the development of products in a broad range of applications.}, language = {en} } @article{WangSarwatWangetal.2020, author = {Wang, Shuang and Sarwat, Mariah and Wang, Peng and Surrao, Denver C. and Harkin, Damien G. and St John, James A. and Bolle, Eleonore C. L. and Forget, Aurelien and Dalton, Paul D. and Dargaville, Tim R.}, title = {Hydrogels with Cell Adhesion Peptide-Decorated Channel Walls for Cell Guidance}, series = {Macromolecular Rapid Communications}, volume = {41}, journal = {Macromolecular Rapid Communications}, number = {15}, doi = {10.1002/marc.202000295}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:20-opus-218031}, year = {2020}, abstract = {A method is reported for making hollow channels within hydrogels decorated with cell-adhesion peptides exclusively at the channel surface. Sacrificial fibers of different diameters are used to introduce channels within poly(ethylene glycol) hydrogels crosslinked with maleimide-thiol chemistry, which are backfilled with a cysteine-containing peptide solution which is conjugated to the lumen with good spatial efficiency. This allows for peptide patterning in only the areas of the hydrogel where they are needed when used as cell-guides, reducing the amount of required peptide 20-fold when compared to bulk functionalization. The power of this approach is highlighted by successfully using these patterned hydrogels without active perfusion to guide fibroblasts and olfactory ensheathing cells—the latter having unique potential in neural repair therapies.}, language = {en} } @article{MechauFrankBakircietal.2021, author = {Mechau, Jannik and Frank, Andreas and Bakirci, Ezgi and Gumbel, Simon and Jungst, Tomasz and Giesa, Reiner and Groll, J{\"u}rgen and Dalton, Paul D. and Schmidt, Hans-Werner}, title = {Hydrophilic (AB)\(_{n}\) Segmented Copolymers for Melt Extrusion-Based Additive Manufacturing}, series = {Macromolecular Chemistry and Physics}, volume = {222}, journal = {Macromolecular Chemistry and Physics}, number = {1}, doi = {10.1002/macp.202000265}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:20-opus-224513}, year = {2021}, abstract = {Several manufacturing technologies beneficially involve processing from the melt, including extrusion-based printing, electrospinning, and electrohydrodynamic jetting. In this study, (AB)\(_{n}\) segmented copolymers are tailored for melt-processing to form physically crosslinked hydrogels after swelling. The copolymers are composed of hydrophilic poly(ethylene glycol)-based segments and hydrophobic bisurea segments, which form physical crosslinks via hydrogen bonds. The degree of polymerization was adjusted to match the melt viscosity to the different melt-processing techniques. Using extrusion-based printing, a width of approximately 260 µm is printed into 3D constructs, with excellent interlayer bonding at fiber junctions, due to hydrogen bonding between the layers. For melt electrospinning, much thinner fibers in the range of about 1-15 µm are obtained and produced in a typical nonwoven morphology. With melt electrowriting, fibers are deposited in a controlled way to well-defined 3D constructs. In this case, multiple fiber layers fuse together enabling constructs with line width in the range of 70 to 160 µm. If exposed to water the printed constructs swell and form physically crosslinked hydrogels that slowly disintegrate, which is a feature for soluble inks within biofabrication strategies. In this context, cytotoxicity tests confirm the viability of cells and thus demonstrating biocompatibility of this class of copolymers.}, language = {en} } @article{BakirciFrankGumbeletal.2021, author = {Bakirci, Ezgi and Frank, Andreas and Gumbel, Simon and Otto, Paul F. and F{\"u}rsattel, Eva and Tessmer, Ingrid and Schmidt, Hans-Werner and Dalton, Paul D.}, title = {Melt Electrowriting of Amphiphilic Physically Crosslinked Segmented Copolymers}, series = {Macromolecular Chemistry and Physics}, volume = {222}, journal = {Macromolecular Chemistry and Physics}, number = {22}, doi = {10.1002/macp.202100259}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:20-opus-257572}, year = {2021}, abstract = {Various (AB)\(_{n}\) and (ABAC)\(_{n}\) segmented copolymers with hydrophilic and hydrophobic segments are processed via melt electrowriting (MEW). Two different (AB)\(_{n}\) segmented copolymers composed of bisurea segments and hydrophobic poly(dimethyl siloxane) (PDMS) or hydrophilic poly(propylene oxide)-poly(ethylene oxide)-poly(propylene oxide) (PPO-PEG-PPO) segments, while the amphiphilic (ABAC)\(_{n}\) segmented copolymers consist of bisurea segments in the combination of hydrophobic PDMS segments and hydrophilic PPO-PEG-PPO segments with different ratios, are explored. All copolymer compositions are processed using the same conditions, including nozzle temperature, applied voltage, and collector distance, while changes in applied pressure and collector speed altered the fiber diameter in the range of 7 and 60 µm. All copolymers showed excellent processability with MEW, well-controlled fiber stacking, and inter-layer bonding. Notably, the surfaces of all four copolymer fibers are very smooth when visualized using scanning electron microscopy. However, the fibers show different roughness demonstrated with atomic force microscopy. The non-cytotoxic copolymers increased L929 fibroblast attachment with increasing PDMS content while the different copolymer compositions result in a spectrum of physical properties.}, language = {en} } @article{BoehmTandonHrynevichetal.2022, author = {B{\"o}hm, Christoph and Tandon, Biranche and Hrynevich, Andrei and Teßmar, J{\"o}rg and Dalton, Paul D.}, title = {Processing of Poly(lactic-co-glycolic acid) Microfibers via Melt Electrowriting}, series = {Macromolecular Chemistry and Physics}, volume = {223}, journal = {Macromolecular Chemistry and Physics}, number = {5}, doi = {10.1002/macp.202100417}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:20-opus-318444}, year = {2022}, abstract = {Polymers sensitive to thermal degradation include poly(lactic-co-glycolic acid) (PLGA), which is not yet processed via melt electrowriting (MEW). After an initial period of instability where mean fiber diameters increase from 20.56 to 27.37 µm in 3.5 h, processing stabilizes through to 24 h. The jet speed, determined using critical translation speed measurements, also reduces slightly in this 3.5 h period from 500 to 433 mm min\(^{-1}\) but generally remains constant. Acetyl triethyl citrate (ATEC) as an additive decreases the glass transition temperature of PLGA from 49 to 4 °C, and the printed ATEC/PLGA fibers exhibits elastomeric behavior upon handling. Fiber bundles tested in cyclic mechanical testing display increased elasticity with increasing ATEC concentration. The processing temperature of PLGA also reduces from 165 to 143 °C with increase in ATEC concentration. This initial window of unstable direct writing seen with neat PLGA can also be impacted through the addition of 10-wt\% ATEC, producing fiber diameters of 14.13 ± 1.69 µm for the first 3.5 h of heating. The investigation shows that the initial changes to the PLGA direct-writing outcomes seen in the first 3.5 h are temporary and that longer times result in a more stable MEW process.}, language = {en} } @article{BoehmStahlhutWeichholdetal.2022, author = {B{\"o}hm, Christoph and Stahlhut, Philipp and Weichhold, Jan and Hrynevich, Andrei and Teßmar, J{\"o}rg and Dalton, Paul D.}, title = {The Multiweek Thermal Stability of Medical-Grade Poly(ε-caprolactone) During Melt Electrowriting}, series = {Small}, volume = {18}, journal = {Small}, number = {3}, doi = {10.1002/smll.202104193}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:20-opus-257741}, year = {2022}, abstract = {Melt electrowriting (MEW) is a high-resolution additive manufacturing technology that places unique constraints on the processing of thermally degradable polymers. With a single nozzle, MEW operates at low throughput and in this study, medical-grade poly(ε-caprolactone) (PCL) is heated for 25 d at three different temperatures (75, 85, and 95 °C), collecting daily samples. There is an initial increase in the fiber diameter and decrease in the jet speed over the first 5 d, then the MEW process remains stable for the 75 and 85 °C groups. When the collector speed is fixed to a value at least 10\% above the jet speed, the diameter remains constant for 25 d at 75 °C and only increases with time for 85 and 95 °C. Fiber fusion at increased layer height is observed for 85 and 95 °C, while the surface morphology of single fibers remain similar for all temperatures. The properties of the prints are assessed with no observable changes in the degree of crystallinity or the Young's modulus, while the yield strength decreases in later phases only for 95 °C. After the initial 5-d period, the MEW processing of PCL at 75 °C is extraordinarily stable with overall fiber diameters averaging 13.5 ± 1.0 µm over the entire 25-d period.}, language = {en} } @article{RobinsonHutmacherDalton2019, author = {Robinson, Thomas M. and Hutmacher, Dietmar W. and Dalton, Paul D.}, title = {The next frontier in melt electrospinning: taming the jet}, series = {Advanced Functional Materials}, volume = {29}, journal = {Advanced Functional Materials}, doi = {10.1002/adfm.201904664}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:20-opus-204819}, pages = {1904664}, year = {2019}, abstract = {There is a specialized niche for the electrohydrodynamic jetting of melts, from biomedical products to filtration and soft matter applications. The next frontier includes optics, microfluidics, flexible electronic devices, and soft network composites in biomaterial science and soft robotics. The recent emphasis on reproducibly direct-writing continual molten jets has enabled a spectrum of contemporary microscale 3D objects to be fabricated. One strong suit of melt processing is the capacity for the jet to solidify rapidly into a fiber, thus fixing a particular structure into position. The ability to direct-write complex and multiscaled architectures and structures has greatly contributed to a large number of recent studies, explicitly, toward fiber-hydrogel composites and fugitive inks, and has expanded into several biomedical applications such as cartilage, skin, periosteum, and cardiovascular tissue engineering. Following the footsteps of a publication that summarized melt electrowriting literature up to 2015, the most recent literature from then until now is reviewed to provide a continuous and comprehensive timeline that demonstrates the latest advances as well as new perspectives for this emerging technology.}, language = {en} }