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Biofabrication and 3D-Bioprinting

Lecture 3
Biofabrication Methods Part I

Prof. Dr.-Ing. Andreas Blaeser


Institute for BioMedical Printing Technology

IDD
https://phys.org/news/2017-02-bio-bot.html

Schematic of a bio-bot:
Engineered skeletal muscle tissue is coupled to a 3-D printed
flexible skeleton. Optical stimulation of the muscle tissue, which is
genetically engineered to contract in response to blue light, makes
IDD the bio-bot walk across a surface in the direction of the light.
Credit: Janet Sinn-Hanlon, University of Illinois
Terminology

Regenerative Tissue
Medicine Engineering

Biofabrication
Bioprinting

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 3


From regenerative medicine to 3D-bioprinting
A short overview on the emerging field of biofabrication

Molding
100000 Regenerative medicine
Tissue engineering

Number of publications
Cell seeding
10000
Tissue Biofabrication
Engineering Bioprinting
… 1000

1896
100 „The regeneration of the blood“
Bioprinting
Regenerative
Medicine 10
Stem cell
Cell therapy
injection
1
1870 1920 1970 2020
Gene
Gene editing Year
therapy

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 4


From regenerative medicine to 3D-bioprinting
A short overview on the emerging field of biofabrication

Molding
100000 Regenerative medicine
Tissue engineering

Number of publications
Cell seeding
10000
Tissue Biofabrication
Engineering Bioprinting
… 1000
1986 Weinberg and Bell
100 „A blood vessel model
Bioprinting constructed from collagen and
Regenerative
Medicine cultured vascular cells“
10
Stem cell
Cell therapy
injection
1
1870 1920 1970 2020
Gene
Gene editing Year
therapy

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 5


From regenerative medicine to 3D-bioprinting
A short overview on the emerging field of biofabrication

Molding
100000 Regenerative medicine
Tissue engineering

Number of publications
Cell seeding
10000
Tissue Biofabrication
Engineering 1993 Langer and Vacanti
Bioprinting
… 1000 „Tissue Engineering“

100
Bioprinting
Regenerative
Medicine 10
Stem cell
Cell therapy
injection
1
1870 1920 1970 2020
Gene
Gene editing Year
therapy

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 6


From regenerative medicine to 3D-bioprinting
A short overview on the emerging field of biofabrication

Molding
100000 Regenerative medicine
Tissue engineering

Number of publications
Cell seeding
10000
Tissue Biofabrication
Engineering Bioprinting
… 1000
2000
100 „Tissue restoration, tissue
Regenerative
Bioprinting engineering and
Medicine 10
regenerative medicine“
Stem cell
Cell therapy
injection
1
1870 1920 1970 2020
Gene
Gene editing Year
therapy

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 7


From regenerative medicine to 3D-bioprinting
A short overview on the emerging field of biofabrication

Molding
100000
Regenerative medicine

Number of publications
Cell seeding Tissue engineering
10000
Tissue Bioprinting
Engineering
… 1000

2006
100 „Bioprinting: A Beginning“
Bioprinting
Regenerative
Medicine 10
Stem cell
Cell therapy
injection
1
1870 1920 1970 2020
Gene
Gene editing Year
therapy

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 8


From regenerative medicine to 3D-bioprinting
A short overview on the emerging field of biofabrication

Biofabrication?
Molding
100000 Regenerative medicine
Tissue engineering

Number of publications
Cell seeding
10000
Tissue Biofabrication
Engineering Bioprinting
… 1000

1985
100 „Collagen Gel for Ocular
Bioprinting
Regenerative Surface“
Medicine 10
Stem cell
Cell therapy
injection
1
1870 1920 1970 2020
Gene
Gene editing Year
therapy

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 9


From regenerative medicine to 3D-bioprinting
A short overview on the emerging field of biofabrication

Biofabrication?
Molding
100000 Regenerative medicine
Tissue engineering

Number of publications
Cell seeding
10000
Tissue Biofabrication
Engineering Bioprinting
… 1000

2009
100 „Biofabrication: a 21st
Bioprinting
Regenerative century manufacturing
Medicine 10 paradigm“
Stem cell
Cell therapy
injection
1
1870 1920 1970 2020
Gene
Gene editing Year
therapy

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 10


From regenerative medicine to 3D-bioprinting
A short overview on the emerging field of biofabrication

Application  Technology Technology  Application

Biofabrication? Regenerative
Molding medicine
Drug testing

Bio-
Cell seeding fabrication Tissue models Toxicity testing
fabrication
Tissue
Engineering
… Disease
Automation & modelling
digitalization
Bioprinting Food
Regenerative
Medicine production
Non-medical
Stem cell applications
Cell therapy Cell-grown
injection technical
products
Gene
Gene editing “The automated generation of biologically functional products with structural
therapy
organization from living cells, bioactive molecules, biomaterials, cell
aggregates such as micro-tissues, or hybrid cell-material constructs, through
bioprinting or bioassembly and subsequent tissue maturation processes.”

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 11


Biofabrication: terminology and definitions

Term Definition
Biological constructs engineered by using in a pre-defined manner cells, biomaterials, and/or
Bio-engineered structures
biological factors alone or in combination with each other.
Formulation of material(s) and biological molecules / cells processed using bioprinting
Bioink
technologies.
A material that is used as (part of) a medical device or an advanced therapy medicinal product
Biomaterials
to replace, restore, or regenerate a tissue or organ and its function.
A cluster of cells, with a spherical shape, typically formed by allowing cell suspension to settle
Cell spheroid
into droplet of media. Electrospinning:

Minimum feature width Smallest detail that can be fabricated using a biofabrication technology.
A biofabrication approach where a biomaterial is used to create a cell-laden scaffold or an
Scaffold-based strategy acellular scaffold with hierarchical ad/or smart surface properties able to steer cell activity and
regenerate a targeted tissue.
A biofabrication approach where a biomaterial is eventually only used as a sacrificial template or
support for cells to be deposited and let organize themselves onto it for the regeneration of a
Scaffold-free strategy
targeted tissue. This approach comprises also the deposition of cells and/or biomolecules only
with no biomaterial support.
The notion, introduced by Malcolm Steinberg, that tissues or multicellular aggregates composed
of motile and adhesive cells have properties analogous to liquids, evidenced by the fact that
Tissue liquidity irregular tissue fragments spontaneously round up into spheroids and two fragments composed of
different cell types mutually envelope each other. Such tissues can be quantified in terms of
apparent tissue surface tension.

Moroni et al., 2018

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 12


Biofabrication and 3D-Bioprinting
From technologies to applications
Te c h n o lo gies A p p lic a tio n s
Lecture 2 Lecture 10
Lecture 3-4 Lecture 11
Cell culture Regenerative
Cell seeding Drug testing
essentials medicine

Tissue Toxicity
Molding Traditional TE models testing
methods
Cell sheet Disease
technol.
Biofabrication modelling

Food
In-situ TE Bioassembly
Non-medical production
applications
Cell-grown
Bioprinting
products
Lectures 5-9 Lecture 12

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 13


Today‘s topic

Te c h n o lo gies A p p lic a tio n s

Cell culture Regenerative


Cell seeding Drug testing
essentials medicine

Tissue Toxicity
Molding Traditional TE models testing
methods
Cell sheet Disease
technol.
Biofabrication modelling

Food
In-situ TE Bioassembly
Non-medical production
applications
Cell-grown
Bioprinting
products

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 14


Traditional tissue engineering process
(in regenerative medicine)

Tissue implantation
3D-Design
• Visual examination
• Medical imaging
• Tool fabrication
(e.g. mold)

Maturation
Biofabrication / -Bioreactor
tissue engineering -Dynamic
Preparation -Individualized tools cultivation
- 3D-design (e.g. molds)
- Biol. building -Manual process
blocks
Biological building blocks
• Living cells
• Growth factors
IDD
• Matrix materials 15
Traditional tissue engineering process
(in regenerative medicine)

Cell seeding

Cell seeding

Molding Traditional TE
methods
Cell sheet In-vitro
technol. cultivation

Scaffold Cell
IDD
fabrication seeding 16
Traditional tissue engineering process
(in regenerative medicine)

Molding / casting

Cell seeding

Molding Traditional TE
methods
Cell sheet In-vitro
technol. cultivation

Mold Cell-matrix
IDD
fabrication casting 15.05.2024 17
Traditional tissue engineering process
(in regenerative medicine)

Cell sheet technology

Cell seeding

Molding Traditional TE
methods
Cell sheet In-vitro
technol. cultivation

Cell sheet Cell sheet


IDD
cultivation winding 15.05.2024 18
Traditional tissue engineering process
(in regenerative medicine)

Cell seeding

Cell seeding

Molding Traditional TE
methods
Cell sheet In-vitro
technol. cultivation

Scaffold Cell
IDD
fabrication seeding 19
What is a scaffold?
“The Air Force Academy's dramatic new
Center for Character and Leadership
Development in Colorado Springs
presented unique challenges.”
Courtesy BrandSafway.
https://www.autodesk.com/redshift/scaffold-design/

IDD Thema des Vortrags | Name des/der Referierenden 15.05.2024 20


Tissue Engineering scaffolds

Scaffold criteria in TE
- Mechanical properties
- Surface chemistry
- Porosity
- Surface area

Porosity influences:
- Permeability
- Vascularization
- Mechanical properties
- Surface area
- Degradation time

Loh et al., 2013

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 21


Scaffold fabrication methods

Lyophilization

Textile Salt leaching /


technology solvent casting

Sponge- / foam-
replication

3D-printing Decellularization

FR/SR: Montazeri et al., 2015 TT: Johnstone et al., 2013


3DP: Huang et al., 2018 LP: Lin et al., 2004
SL/SC: Yu et al., 2016 DC: Baiocchini et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 22


https://ethz.ch/de/news-und-veranstaltungen/eth-
IDD
news/news/2017/12/3d-gedruckte-minifabriken.html Thema des Vortrags | Name des/der Referierenden 15.05.2024 23
3D-printed scaffolds for Tissue Engineering

Additive Manufacturing (AM)

3D-CAD File
3D-printing
for scaffold fabrication

Data transfer

STL-File
Layer-by-layer 3D-object: cleaning, 3D-bioprinting
fabricationof3D- finishing, sterilization
object

Slicing
http://medfab.de/wp-
#1 Data generation #2 Printingprocess #3 Post processing
content/uploads/2015/08/Prozesskette-
Additive-Manufacturing-3D_Druck-.png

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 24


3D-printed scaffolds for Tissue Engineering

Additive Manufacturing (AM)

3D-CAD File
3D-printing
for scaffold fabrication

Data transfer

STL-File
Layer-by-layer 3D-object: cleaning, 3D-bioprinting
fabricationof3D- finishing, sterilization
object

Slicing
http://medfab.de/wp-
#1 Data generation #2 Printingprocess #3 Post processing
content/uploads/2015/08/Prozesskette-
Additive-Manufacturing-3D_Druck-.png

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 25


3D-printed scaffolds for Tissue Engineering

3D-printing
for scaffold fabrication

3D-bioprinting

Yang et al., 2018

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 26


3D-printed Tissue Engineering scaffolds

 Material classes
• Metals, ceramics
• Polymers, hydrogels
• Native ECM
 Advantages
• High precision
• High reproducibility
 Disadvantages
• Process has to be adapted for each material individually
• Time-consuming process development and optimization
 Applicable tissue types
• Adipose tissue, bone, cartilage, dental pulp, heart valve, liver, muscle,
myocardium, nerve, skin, trachea

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 27


3D-printed scaffolds for Tissue Engineering

Primary porosity
(porosity by design)

Abbasi et al., 2019


Zhakeyev et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 28


3D-printed scaffolds for Tissue Engineering

Primary porosity Secondary porosity


(porosity by design) (porosity by process)
Surface

Alginate

500 µm

Internal

2 mm

Egorov et al., 2016


Zhakeyev et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 29


3D-printed scaffolds for Tissue Engineering

Microextrusion Fused filament fabrication

Direct drop-on-demand printing


Zhakeyev et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 30


3D-printed scaffolds for Tissue Engineering

Powder bed / Binder jetting Photopolymer


3D-printing inkjet 3D-printing
Zhakeyev et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 31


3D-printed scaffolds for Tissue Engineering

Selective laser sintering Stereolithography Digital light processing


(SLS) (SLA) (DLP)
Zhakeyev et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 32


3D-printed scaffolds for Tissue Engineering

SLA DLP
Precision ▲ Precision ▼
www.formlabs.com Speed ▼ Speed ▲
Selective laser sintering Stereolithography Digital light processing
(SLS) (SLA) (DLP)
Zhakeyev et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 33


Example: 3D-printed scaffold for trachea repair

https://anjungsainssmkss.wordpress.com/2011/05/01/11/

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 34


Example: 3D-printed scaffold for trachea repair
Step #1: 3D-data generation

Tissue implantation
3D-Design
• Visual examination
• Medical imaging
• Tool fabrication
(e.g. mold)

Maturation
Biofabrication / -Bioreactor
tissue engineering -Dynamic
Preparation -Individualized tools cultivation
- 3D-design (e.g. molds)
- Biol. building -Manual process
blocks
Biological building blocks
• Living cells
• Growth factors
IDD
• Matrix materials 35
Example: 3D-printed scaffold for trachea repair

Gao et al., 2017 https://pethelpful.com/rabbits/Bunny-Breed-Guide-New-Zealand-White-Rabbit

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 36


Example: 3D-printed scaffold for trachea repair
Step #2: Scaffold fabrication

Cell seeding (in blood vessel TE)

Cell seeding

Molding Traditional TE
methods
Cell sheet In-vitro
technol. cultivation

Scaffold Cell
IDD
fabrication seeding 37
Example: 3D-printed scaffold for trachea repair

Gao et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 38


Example: 3D-printed scaffold for trachea repair
Step #3 and #4: Cell seeding and cultivation (2-4 weeks)

Cell seeding (in blood vessel TE)

Cell seeding

Molding Traditional TE
methods
Cell sheet In-vitro
technol. cultivation

Scaffold Cell
IDD
fabrication seeding 39
Example: 3D-printed scaffold for trachea repair

Group I
2 weeks
pre-cultivation

Group II
4 weeks
pre-cultivation

Figure 4. Representative photomacrographs and histological stainings of tissue-engineered


tracheas after reconstruction in vitro. (A–D) Group I, TET in vitro cultured with chondrocytes for
2 weeks. (E–H) Group II, TET in vitro cultured with chondrocytes for 4 weeks. (A,E) Gross view
of TET. (B,F) Histology staining with H&E. (C,G) Histology staining with Safranin O. (D,H)
Histology staining with Toluidine blue. Scale bars: 100μm. (P: PCL scaffold bars).

Gao et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 40


Example: 3D-printed scaffold for trachea repair
#5 Implantation

Cell seeding (in blood vessel TE)

Cell seeding Implantation

Molding Traditional TE
methods
Cell sheet In-vitro
technol. cultivation

Scaffold Cell
IDD
fabrication seeding 41
Example: 3D-printed scaffold for trachea repair

Gao et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 42


Example: 3D-printed scaffold for trachea repair

Gao et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 43


Example: 3D-printed scaffold for trachea repair

Gao et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 44


Example: 3D-printed scaffold for trachea repair
Future optimization

Most frequent reason for death of the animals:


Formation of granulation tissue.

Granulation formation
(67-88 % cause of death)

Gao et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 45


Example: 3D-printed scaffold for trachea repair
Future optimization

Bacterial infection
Secretion

Infection and pneumonia Inflammation

Invading
connective tissue

Granulation formation
(67-88 % cause of death)

Gao et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 46


Example: 3D-printed scaffold for trachea repair
Future optimization


Bacterial infection
Secretion


Infection and pneumonia Inflammation

Invading
connective tissue

Epithelialization

Respiratory
epithelium
Granulation formation
(67-88 % cause of death)

Gao et al., 2017 Thiebes et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 47


Example: 3D-printed scaffold for trachea repair
Future optimization


Bacterial infection
Secretion


Infection and pneumonia Inflammation

Invading


connective tissue

Epithelialization

Vascularization

Respiratory
epithelium
Supports
epithelial ingrowth
Gao et al., 2017 Thiebes et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 48


Example of our own work in this field
3D-printed bone TE scaffold

Microporous
Infill-spinning

Mesoporous
main body

„Lego“-approach
stackable scaffold
modules

Söhling et al., 2020

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 49


Example of our own work in this field
3D-printed bone TE scaffold

Microporous
Infill-spinning

Mesoporous
main body

„Lego“-approach
stackable scaffold
modules

Söhling et al., 2020

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 50


Scaffold fabrication methods

Lyophilization

Textile Salt leaching /


technology solvent casting

Sponge- / foam-
replication

3D-printing Decellularization

FR/SR: Montazeri et al., 2015 TT: Johnstone et al., 2013


3DP: Huang et al., 2018 LP: Lin et al., 2004
SL/SC: Yu et al., 2016 DC: Baiocchini et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 51


Textile engineering
and medicine?

IDD Karl Meyer Textilmaschinenfabrik GmbH | Product catalog: RDJ 5/1: We 210/1/09/04/5/11/19 | www.karlmayer.com
https://www.oz-verlag.de/trend-weben-tolle-strukturen-aus-garn-und-wolle/

IDD
Textile engineering technologies

 Highly industrialzed processes

 High scale production

 Versatile production modalities


• Electrospinning
• Weaving
• Knitting
• Warp-knitting
• Braiding

Karl Meyer Textilmaschinenfabrik GmbH | Product catalog: RDJ 5/1: We 210/1/09/04/5/11/19 | www.karlmayer.com

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 54


Textile engineering technologies

 Material classes
• Polymers
• (and metals, ceramics, hydrogels)
 Advantages
• Controllable porosity &
mechanical properties
• Drapable
• Broad polymer spectrum
 Disadvantages
• Mainly planar or cylindrical tissues
 Applicable tissue types
• Adipose tissue, blood vessels, bladder, bone, cartilage, cornea, dental pulp,
gingiva, heart valve, heart, kidney, liver, muscle, myocardium, nerve, pancreas,
pelvic floor, skin, tendon, trachea

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 55


Textile engineering technologies

Polymer
properties Yarn type
Adjustable
Fiber
properties porosity &
mechanics
Production Production
Yarn
properties settings technology

Fiber Textile Scaffold

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 56


Textile engineering technologies
Source: Institut für Textiltechnik, RWTH Aachen

Various
geometries Hollow

Monofilament Electrospinning Warp-knitting

Segmented
Side-by-side pie

Multifilament Multi-layer Core-shell Texturized yarn Weaving Braiding

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 57


Textile engineering technologies

2mm

Textile elasticity = Structure elasticity + Fiber elasticity


1mm

1mm

Source: Institut für Textiltechnik, RWTH Aachen

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 58


Textile engineering technologies

0 % TPU Doppel Jersey


Charmeuse 2mm
50 % TPU
Force (N)

100 % TPU

Textile elasticity = Structure elasticity + Fiber elasticity


1mm

Strain (%)
1mm

Source: Institut für Textiltechnik, RWTH Aachen

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 59


Textile engineering technologies
Electrospinning
https://bioinicia.com/electrospinning-machine-specifications/

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 60


Textile engineering technologies
Electrospinning

Chen et al., 2019

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 61


Textile engineering technologies
Electrospinning

Hardick et al., 2014

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 62


Textile engineering technologies
Electrospinning

Wang et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 63


Example: Electron spun sheets in nerve tissue repair

Ortho Cell: CelGro™ Nerve Repair:


https://www.youtube.com/watch?v=wFa95baSH84

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 64


Example: Electron spun sheets in nerve tissue repair

Peripheral nerve damage

Conventional therapy
• Removal of damaged
section
• Suture of nerve ends
• Risk of
1) Scar formation
2) Wrongly connected
nerve ends

Textile sheet
• Electrospun textile
• Wrapped around nerve
ends
• Benefits
1) Keeping growths factors
inside wound
2) Promote nerve repair
3) Prevent ingrowth of
Ortho Cell: CelGro™ Nerve Repair: neighboring tissue
https://www.youtube.com/watch?v=wFa95baSH84

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 65


Example of our own work in this field
Textile scaffolds for (heart) muscle TE
Extruder

Molten
geschmolzene
polymer
Spinnmasse
Spinnpumpe
Spinning pump
Fiber Fiber (TPU, PE, PCL, or PVDF)
Spinndüse
Spinneret
Spinning

Warp-knitting
Kaltluft
Cooling air Aufwickel-
Winding
vorrichtung
machine

Verstrecken
Drawing

Textile
scaffold

Karl Meyer Textilmaschinenfabrik GmbH | Product catalog: RDJ


5/1: We 210/1/09/04/5/11/19 | www.karlmayer.com
Source: Institut für Textiltechnik, RWTH Aachen

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 66


Example of our own work in this field
Elastic TPU-mesh

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 67


Example of our own work in this field
Contractile cardiomyocyte-laden PVDF scaffold

Cardiomyocytes on PVDF scaffold


following 20 days in-vitro cultivation

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 68


Scaffold fabrication methods

Lyophilization

Textile Salt leaching /


technology solvent casting

Sponge- / foam-
replication

3D-printing Decellularization

FR/SR: Montazeri et al., 2015 TT: Johnstone et al., 2013


3DP: Huang et al., 2018 LP: Lin et al., 2004
SL/SC: Yu et al., 2016 DC: Baiocchini et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 69


http://t3.gstatic.com/images?q=tbn:ANd9GcQZjFb7c7kEcbj2N-
emn_UfkCHoqNcuIEW7xPb0RhYcdBujtNuo4Tg4sQVF1DoFwh000S1ApKDWXMdT0cE6W7E

IDD
Sponge- /
foam-replication

Thema des Vortrags | Name des/der Referierenden


15.05.2024
70
Sponge- / foam-replication

Sergeeva et al., 2019

https://www.britannica.com/science/periosteum

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 71


Sponge- / foam-replication

Kränzlin and Niederberger, 2015

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 72


Sponge- / foam-replication

 Material classes
• Metals, ceramics
 Porosity
• Depends on sponge
properties
 Advantages
• Simple & inexpensive
• High porosity
 Disadvantages
• Reproducibility
• Limited to certain materials
 Applicable tissue types
• Mainly bone
Kränzlin and Niederberger, 2015

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 73


Sponge- / foam-replication

 Material classes
• Metals, ceramics
 Porosity
• Depends on sponge
properties
 Advantages
• Simple & inexpensive
• High porosity
 Disadvantages
• Reproducibility
• Limited to certain materials
 Applicable tissue types Ceramic scaffold with Gervaso et al., 2012

• Mainly bone • > 500 µm mean pore size


• > 90 % mean porosity

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 74


Scaffold fabrication methods

Lyophilization

Textile Salt leaching /


technology solvent casting

Sponge- / foam-
replication

3D-printing Decellularization

FR/SR: Montazeri et al., 2015 TT: Johnstone et al., 2013


3DP: Huang et al., 2018 LP: Lin et al., 2004
SL/SC: Yu et al., 2016 DC: Baiocchini et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 75


https://www.healthline.com/nutrition/different-types-of-salt

Salt leaching /
solvent casting

IDD Thema des Vortrags | Name des/der Referierenden 15.05.2024 76


Salt leaching / solvent casting

Worthington et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 77


Salt leaching / solvent casting

 Material classes
• Polymers, hydrogels
 Porosity
• Depends on salt particle dimensions
 Advantages
• Simple & inexpensive
• Adjustable porosity
 Disadvantages
Worthington et al., 2016
• Reproducibility
• Uncontrolled pore interconnectivity
• Limited material selection
 Applicable tissue types
• Blood vessels, bladder, bone, cartilage, cornea, heart valve, muscle, nerve, skin

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 78


Salt leaching / solvent casting

Particle size Porosity (%) Mean pore size


(µm) (µm)
< 50 83.13 36.47
50-100 80.85 82.73
100-200 79.50 123.00
> 200 77.13 243.47

Yu et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 79


Scaffold fabrication methods

Lyophilization

Textile Salt leaching /


technology solvent casting

Sponge- / foam-
replication

3D-printing Decellularization

FR/SR: Montazeri et al., 2015 TT: Johnstone et al., 2013


3DP: Huang et al., 2018 LP: Lin et al., 2004
SL/SC: Yu et al., 2016 DC: Baiocchini et al., 2016

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 80


Collapse of the
Historical Archive of Cologne
March 3rd, 2009
IDD
https://www.ksta.de/koeln/der-tag--der-koeln-veraenderte-das-minutenprotokoll-der-stadtarchiv-katastrophe-32126188
Thema des Vortrags | Name des/der Referierenden 15.05.2024 81
Collapse of the Historical Archive of Cologne

The Historical Archive of the City of


Cologne was considered one of the
largest city archives in Germany. It
contained documents from more than
a thousand years of Cologne and
Rhineland history, including 65,000
documents, 104,000 maps and half
a million photos.
https://www.ksta.de/koeln/--5866856

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 82


https://www.stadt-koeln.de/politik-und-
verwaltung/presse/mitteilungen/13024/index.html

IDD
Lyophilization?

Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser


15.05.2024
83
Lyphilization / freeze-drying process

Abbasi et al., 2019

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 84


Lyphilization / freeze-drying process

Lyphiization
The process of lyophilization,
involving three stages that
remove water from a sample
by freezing it and placing it
under specific vacuum
pressures and temperatures

https://www.gelifesciences.com/en/us/solutions/genomics/products-and-
technologies/custom-genomic-services/lyo-stable/advantages-of-lyophilization

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 85


Lyphilization / freeze-drying process

 Material classes
• Hydrogels
• (and autogenic, allogenic, or xenogenic
acellular matrix)
 Advantages Abbasi et al., 2019
• Simple & inexpensive
• Applicable for hydrogels
 Disadvantages
• Reproducibility
• Limited materials
 Applicable tissue types
• Blood vessels, bladder, bone, cartilage,
cornea, heart valve, liver, muscle, nerve,
skin, tendon https://www.gelifesciences.com/en/us/solutions/genomics/products-and-
technologies/custom-genomic-services/lyo-stable/advantages-of-lyophilization

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 86


Lyophilization of hydrogels

Lu et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 87


Lyophilization of hydrogels

Tunable mechanical properties


and porosity
Poro size: 52.3-426.5 µm
E-Modulus: 18.6-58.8 kPa
Lu et al., 2017

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 88


Lyphilization with spatially controlled porosity

https://www.cryolifesciences.de/en/biomaterial-development/3d-structure-on-demand/

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 89


Example: Lyophilized collagen sponges with
directed pore geometry for nerve tissue repair

Peripheral nerve damage


Conventional therapy
• Removal of damaged
section
• Suture of nerve ends
• Risk of
1) Scar formation
2) Wrongly connected
nerve ends

Textile sheet
• Electrospun textile
• Wrapped around nerve
ends
• Benefits
1) Keeping growths factors
inside wound
2) Promote nerve repair
3) Prevent ingrowth of
Ortho Cell: CelGro™ Nerve Repair: neighboring tissue
https://www.youtube.com/watch?v=wFa95baSH84

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 90


Example: Lyophilized collagen sponges with
directed pore geometry for nerve tissue repair
Peripheral nerve damage
Pore orientation
Lyophilized collagen
sponge with directed
pore geometry as nerve
guidance

Critical size damages > 2-3 cm

Ortho Cell: CelGro™ Nerve Repair:


https://www.youtube.com/watch?v=wFa95baSH84

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 91


Example: Lyophilized collagen sponges with
directed pore geometry for nerve tissue repair

Lyophilized collagen
sponge with directed
pore geometry as nerve
guidance

Matricel GmbH, Aachen und RWTH Aachen:


http://www.matricel.net/
http://www.matricel.net/de/forschung/neuromaix.html

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 92


Example: Lyophilized collagen sponges with
directed pore geometry for nerve tissue repair

Peripheral nerve damage

Conventional therapy Risk of


• Removal of damaged section 1) Scar formation
• Suture of nerve ends 2) Wrongly connected nerve ends

Textile sheet Benefits


• Electrospun textile 1) Keeping growths factors inside wound
• Wrapped around nerve ends 2) Promote nerve repair
3) Prevent ingrowth of neighboring tissue

Lyophilized hydrogels Benefits


• Direct pore orientation 1) Same as textile sheet (see above)
• Can be sutured or applied 2) Direct pore orientation further
improves correct nerve cell ingrowths
with cell sheet
3) Nerve cell guidance enables bridging
critical size defects > 2-3 cm
Ortho Cell: CelGro™ Nerve Repair:
https://www.youtube.com/watch?v=wFa95baSH84

IDD Biofabrication Part I | Prof. Dr.-Ing. Andreas Blaeser 15.05.2024 93


Cell seeding TE
Overview of scaffold fabrication methods
Fabrication Material Advantages (+) / Applications
method classes disadvantages (-)
3D-printing Metals, ceramics, + High precision Adipose tissue, bone, cartilage, dental
polymers, hydrogels, + High reproducibility pulp, heart valve, liver, muscle,
native ECM - Time-consuming process myocardium, nerve, skin, trachea
development
Sponge- / foam- Metals, ceramics + Simple & inexpensive Mainly bone
replication + High porosity
- Reproducibility
- Limited material selection
Salt leaching / Polymers, hydrogels + Simple & inexpensive Blood vessels, bladder, bone, cartilage,
solvent casting + Adjustable porosity cornea, heart valve, muscle, nerve, skin
- Reproducibility
- Uncontrolled pore interconnectivity
- Limited materials
Lyophilization Hydrogels + Simple & inexpensive Blood vessels, bladder, bone, cartilage,
(and autogenic, + Applicable for hydrogels cornea, heart valve, liver, muscle, nerve,
allogenic, or xenogenic - Reproducibility skin, tendon
acellular matrix) - Limited materials
Textile technology Polymers + Controllable porosity & tensile Adipose tissue, blood vessels, bladder,
(and metals, ceramics, strength bone, cartilage, cornea, dental pulp,
hydrogels) + Drapable gingiva, heart valve, heart, kidney, liver,
+ Broad polymer spectrum muscle, myocardium, nerve, pancreas,
- Mainly planar or cylindrical tissues pelvic floor, skin, tendon, trachea
Decellularization

IDD Thema des Vortrags | Name des/der Referierenden 15.05.2024 94


Thank you for your attention

Technical University of Darmstadt


Institute for BioMedical Printing Technology
Prof. Dr.-Ing. Andreas Blaeser
Magdalenenstr. 2
64289 Darmstadt
Germany

https://www.idd.tu-darmstadt.de

IDD

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