The properties of polylactic acid (PLA) filaments have not yet been analysed in detail, and they are strongly affected by the extrusion process used in some additive manufacturing systems. Here we present the mechanical, thermal, physical, and fractographical properties of an extruded filament (not the bulk material or scaffolds), the basic building block of any PLA structure printed via material extrusion. This research aims to create a reference point for the modelisation of additively manufactured structures via extrusion processes, as the main building block is characterised in detail for a deep understanding. Furthermore, we investigated the natural ageing (up to one year), the effect of the printing (extruding) temperature (180 and 190 °C), and the effect of the crosshead speed during the tensile tests (10⁻¹ to 10² mm/min) to provide a deeper analysis of the material. The results showed that the material extruded at 190 °C performed better than the material extruded at 180 °C. However, after one hundred days of natural ageing, both materials behaved similarly. This was related to the flow-induced molecular orientation during the extrusion. The crosshead rate produced a logarithmic increase of the mechanical properties, consistent with the Eyring model. Additionally, the ageing produced significant changes in both the elastic modulus and the yield strength: from 2.4 GPa and 40 MPa, in one-day-aged samples, up to 4 GPa and 62 MPa once entirely aged. Finally, it was observed that the glass transition and the enthalpic relaxation increased with ageing, agreeing with the Kohlraushch–William–Watts model.

In vivo, cells reside in a 3D porous and dynamic microenvironment. It provides biochemical and biophysical cues that regulate cell behavior in physiological and pathological processes. In the context of fundamental cell biology research, tissue engineering, and cell-based drug screening systems, a challenge is to develop relevant in vitro models that could integrate the dynamic properties of the cell microenvironment. Taking advantage of the promising high internal phase emulsion templating, we here designed a polyHIPE scaffold with a wide interconnected porosity and functionalized its internal 3D surface with a thin layer of electroactive conducting polymer poly(3,4-ethylenedioxythiophene) (PEDOT) to turn it into a 4D electroresponsive scaffold. The resulting scaffold was cytocompatible with fibroblasts, supported cellular infiltration, and hosted cells, which display a 3D spreading morphology. It demonstrated robust actuation in ion- and protein-rich complex culture media, and its electroresponsiveness was not altered by fibroblast colonization. Thanks to customized electrochemical stimulation setups, the electromechanical response of the polyHIPE/PEDOT scaffolds was characterized in situ under a confocal microscope and showed 10% reversible volume variations. Finally, the setups were used to monitor in real time and in situ fibroblasts cultured into the polyHIPE/PEDOT scaffold during several cycles of electromechanical stimuli. Thus, we demonstrated the proof of concept of this tunable scaffold as a tool for future 4D cell culture and mechanobiology studies.