Numerical model of jet formation during melt electrowriting for fabrication of precise structures

Abstract

Melt electrowriting (MEW) is an innovative technique for fabricating 3D porous materials or scaffolds with microscale architectures. However, the multitude of printing parameters makes precise control over the placement of microscale polymer fibers challenging. This study presents a new strategy for creating complex 3D structures using multiparametric MEW technology, which enhances printing accuracy with minimal human intervention. We developed and validated a numerical model to simulate jet formation and predict the critical translational speed (CTS). This model can precisely identify the effects of numerous printing parameters and improve printing efficiency and accuracy while reducing costs, thus facilitating precise MEW deposition. Using this approach, we manufactured soft, stretchable constructs with a high surface area optimized through fine-tuned printing parameters. This straightforward and efficient technology enables the design of high-sensitivity strain sensors for monitoring human motion and stretchable devices for circuit protection. Furthermore, we examined the effect of printing accuracy and fiber orientation on cellular organization. Immunochemical staining demonstrated that aligned and high-precision scaffolds promote oriented growth. Additionally, the curved MEW structures open new avenues for exploring the combined effects of topographical cues and mechanical stimulation on nerve cell behaviors. This printing strategy provides valuable insights for future research on complex patterns using MEW for flexible electronics and tissue engineering.