With the increasing awareness of environmental protection and sustainable manufacturing, the environmental impact of laser additive manufacturing (LAM) technology has been attracting more and more attention. Aiming to quantitatively analyze the energy consumption and extract possible ways to save energy during the LAM process, this investigation studies the effects of input variables including laser power, scanning speed, and powder feed rate on the overall energy consumption during the laser deposition processes. Considering microhardness as a standard quality, the energy consumption of unit deposition volume (ECUDV, in J/mm³) is proposed as a measure for the average applied energy of the fabricated metal part. The potential energy-saving benefits of the ultrasonic vibration–assisted laser engineering net shaping (LENS) process are also examined in this paper. The experimental results suggest that the theoretical and actual values of the energy consumption present different trends along with the same input variables. It is possible to reduce the energy consumption and, at the same time, maintain a good part quality and the optimal combination of the parameters referring to Inconel 718 as a material is laser power of 300 W, scanning speed of 8.47 mm/s and powder feed rate of 4 rpm. When the geometry shaping and microhardness are selected as evaluating criterions, American Iron and Steel Institute (AISI) 4140 powder will cause the largest energy consumption per unit volume. The ultrasonic vibration–assisted LENS process cannot only improve the clad quality, but can also decrease the energy consumption to a considerable extent.

Tissue engineering is a promising area that is aimed at tissue regeneration and wound repair. Sodium alginate (SA) has been widely used as one of the most biocompatible materials for tissue engineering. The cost-efficiency and rapid gel ability made SA attractive in would healing and regeneration area. To improve printability and elasticity, many hydrogel-based bioinks were developed by mixing SA with other natural or synthetic polymers. In this paper, composite SA/COL bioink was used for the bioprinting of artificial cartilage tissue mimicries. The results showed that the concentration of both SA and COL has significant effects on filament diameter and merging. A higher concentration of the bioink solution led to better printing fidelity and less deformation. Overall, a higher SA concentration and a lower COL concentration contributed to a lower shrinkage ratio after crosslinking. In summary, the SA/COL composite bioink has favorable rheological properties and this study provided material composition optimization for future bioprinting of engineered tissues.

There has been substantial progress in tissue engineering of biological substitutes for medical applications. One of the major challenges in development of complex tissues is the difficulty of creating vascular networks for engineered constructs. The diameter of current artificial vascular channels is usually at millimeter or submillimeter level, while human capillaries are about 5 to 10 µm in diameter. In this paper, a novel core-sheath electrospinning process was adopted to fabricate nanoporous microtubes to mimic the structure of fenestrated capillary vessels. A mixture of polylactic acid (PLA) and polyethylene glycol (PEO) was used as the sheath solution and PEO was used as the core solution. The microtubes were observed under a scanning electron microscope and the images were analyzed by ImageJ. The diameter of the microtubes ranged from 1–8 microns. The diameter of the nanopores ranged from 100 to 800 nm. The statistical analysis showed that the microtube diameter was significantly influenced by the PEO ratio in the sheath solution, pump rate, and the viscosity gradient between the sheath and the core solution. The electrospun microtubes with nanoscale pores highly resemble human fenestrated capillaries. Therefore, the nanoporous microtubes have great potential to support vascularization in engineered tissues.

Vascularization for tissue engineering applications has been challenging over the past decades. Numerous efforts have been made to fabricate artificial arteries and veins, while few focused on capillary vascularization. In this paper, core-sheath electrospinning was adopted to fabricate nanoporous microtubes that mimic the native capillaries. The results showed that both solution viscosity and polyethylene oxide (PEO) ratio in polycaprolactone (PCL) sheath solution had significant effects on microtube diameter. Adding PEO into PCL sheath solution is also beneficial to surface pore formation, although the effects of further increasing PEO showed mixed results in different viscosity groups. Our study showed that the high viscosity group with a PCL/PEO ratio of 3:1 resulted in the highest average microtube diameter (2.14 µm) and pore size (250 nm), which mimics the native human capillary size of 1–10 µm. Therefore, our microtubes show high potential in tissue vascularization of engineered scaffolds.

As a versatile nanofiber manufacturing technique, electrospinning has been widely used for tissue engineering scaffold fabrication. However, it remains challenging to create scaffolds with anisotropic microstructure close to native tissues. This article presented a novel electrospinning configuration to generate fibrous mat with microstructure gradient. A series of proof-of-concept tests were performed to investigate the effects of process parameters on the gradient of nanofiber morphology and mat attributes. The technique developed in this study showed great potentials as a fabrication platform for heterogenous nanofiber products.