Microfluidic Bubble-Templating Multinozzle 3D Printing for Preparations of Macroporous Hydrogels with Ordered Pores of Large Size Ranges

A strategy for fabrication of macroporous hydrogels through 3D printing assisted by molding and multiple microfluidic bubble-templating nozzles is proposed here. This approach aims to address the challenges faced by methods for 3D printing macroporous hydrogels, such as difficulties in precisely controlling the spatial distribution of macropores, limited porosity, and low resolution of external boundaries due to the poor mechanical properties of hydrogel solutions as printing ink. In this method, fast-switching microfluidic bubble-templating nozzles of varying sizes allowed for precise control of target pore sizes over a wide range. Cavities of polydimethylsiloxane (PDMS) molds were used to define the overall external shape of the hydrogels and enhance the resolution of the boundaries. During the printing process, the laminar shear force generated by a coaxial microfluidic system generated microbubbles which were then injected into the PDMS mold cavities. The spatial distribution of the microbubble clusters within the cavities was controlled by a 3D motion module. Finally, macroporous hydrogels with a pore size range of 238-930 μm were fabricated while avoiding millimeter round corners on the boundaries. A control precision of pore sizes was about 60 μm. Most importantly, this strategy broke through the space occupancy limitations of pores in traditional 3D printing methods for macroporous hydrogels. The space occupancy of pores could reach a maximum of about 87% within a single layer.