Custom FDM-based bioprinter with heated nozzle : optimizing slicer settings for precision printing using a print quality index

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Meyer, Leif O. ; Jérôme, Valérie ; Freitag, Ruth:
Custom FDM-based bioprinter with heated nozzle : optimizing slicer settings for precision printing using a print quality index.
In: Biomedical Materials. Bd. 20 (2025) . - 035030.
ISSN 1748-6041
DOI: https://doi.org/10.1088/1748-605X/add230

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Abstract

Bioprinting of microtissues has become a standard technique in medical and biotechnological research, offering a more accurate replication of the in vivo setting than conventional 2D cell culture. However, widespread adoption is limited by the absence of a universally accepted printing benchmark—common in standard fused deposition modeling (FDM) printing, as well as the high cost and restricted customizability of commercial bioprinters. This study introduces a method to convert a standard FDM printer into a bioprinter. All cell-contacting components are biocompatible and autoclavable, while the printer body can be UV-sanitized. Using a heated FDM printhead, we used the thermal properties of alginate-gelatin bioinks to achieve high-resolution 3D printing. A key achievement was the developed print quality index (PQI) method, which correlates nozzle temperature with bioink flow behavior, streamlining optimization of slicer settings. Guided by PQI, we reproducibly bioprinted complex alginate-gelatin structures with high quality and dimensional/geometric accuracy. A case study using recombinant HuH7EGFP cell-laden hydrogels demonstrated long-term cell proliferation, confirming high viability. Given its efficiency, the PQI method has the potential to become the missing printing benchmark for slicer optimization in bioprinting. The presented approach significantly advances the accessibility of sophisticated bioprinting technology to interested research groups worldwide.