Development of screw-type printheads for adaptation in conventional filament 3D printers: a low-cost alternative for the production of printed bone scaffolds

• Grant number: 25/11844-2
• Support Opportunities: Regular Research Grants
• Start date: October 01, 2025
• End date: September 30, 2026
• Field of knowledge: Physical Sciences and Mathematics - Chemistry - Physical-Chemistry
• Principal Investigator: Bianca Chieregato Maniglia
• Grantee: Bianca Chieregato Maniglia
• Host Institution: Instituto de Química de São Carlos (IQSC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
• City of the host institution: São Carlos
• Associated research grant: 20/08727-0 - Starch modification by green methods for elaboration via 3D printing of bone scaffolds activated by the presence of hydroxyapatite nanoparticles replaced by Sr2+, AP.JP
• Associated scholarship(s): 25/22078-9 - Development of screw-type print heads for adaptation to conventional filament 3D printers: a low-cost alternative for the production of 3D-printed bone scaffolds., BP.IC

Abstract

Extrusion-based 3D printing has emerged as a promising technology for the fabrication of personalized bone grafts in regenerative medicine. However, it still faces limitations related to the rheological properties of formulations and the high cost of commercially available equipment, particularly within the Brazilian market. This project proposes the development of two extrusion printheads adaptable to a conventional filament-based 3D printer, aiming to enable the processing of semi-fluid materials. One printhead will operate via piston extrusion, suitable for low-viscosity formulations, while the other will use screw extrusion, allowing the processing of materials with a broader range of rheological profiles. The project includes the design, modeling, fabrication, and testing of the printheads, as well as the mechanical and electrical adaptation of the printer and its software configuration. Additionally, starch-based hydrogel formulations combined with hydroxyapatite will be developed, with their rheological properties characterized and tested using the developed printheads. This initiative is expected to democratize access to semi-fluid 3D printing in the medical field, expanding the possibilities for producing customized bone grafts and biomedical devices. (AU)