3D bioprinting of hydrogel/ceramic composites with hierarchical porosity

Abstract Direct 3D bioprinting of bioreactors containing microorganisms embedded inside hydrogel structures is a promising strategy for biotechnological applications. Nevertheless, microporous hydrogel networks hinder the supply of nutrients and oxygen to the cell and limit cell migration and proliferation. To overcome this drawback, we developed a feedstock for 3D bioprinting structures with hierarchical porosity. The feedstock is based on a highly particle-filled alumina/alginate nanocomposite gel with immobilized E. coli bacteria with the protein ovalbumin acting as foaming agent. The foamed nanocomposite is shaped into a porous mesh structure by 3D printing. The pore radius diameters inside the non-printed, non-foamed nanocomposite structure are below 10 µm, between 10 and 500 µm in the albumin-stabilized foam and with additional pores in the range of 0.5 and 1 mm in the printed mesh structure. The influence of albumin on the bubbles and hence pore formation was analyzed by means of interfacial shear rheology and porosity measurements with X-ray microtomography (µCT). Furthermore, averaged diffusion coefficients of water in printed and non-printed samples with different albumin concentrations were recorded using nuclear magnetic resonance (NMR) tomography to assess the water content in the porous structure. Moreover, the effective viability and accessibility of embedded E. coli cells were analyzed for various material compositions. Here, the addition of albumin induced bacterial growth and the porosity increased the effective viability of the embedded bacteria, most likely because of enhanced accessibility of the cells. The experimental results demonstrate the potential of this approach for producing macroscopic bioactive materials with complex 3D geometries as a platform for novel applications in bioprocessing.