Extrusion-based 3D printing for thermoplastic polymers manifests potential for the fabrication of biocompatible and biodegradable scaffolds. However, the uncontrollable shape of printed filaments usually negatively impacts on the printing processes. Non-uniform temperature in the print head is a primary cause of inaccuracy in the diameter of filaments formed during the process of extruding thermoplastic polymers. Therefore, the temperature distribution inside the print head must be controlled accurately. This study developed a novel print head configuration with two groups of controllable heat sources for extrusion-based printing of thermoplastic polymers. Subsequently, a numerical thermal analysis based on the finite element method (FEM) was conducted to investigate the temperature field in the print head during the heating process. Moreover, a temperature control strategy is proposed under which the temperature distribution of the print head can be regulated. The temperature uniformity can be improved with the proposed temperature control strategy. Lastly, groups of printing trials were implemented, and the printed filaments showed excellent uniformity of diameter when temperature distribution uniformity was controlled in the print head.

Medical hydrogels represent a promising solution for the treatment of corneal diseases and trauma, offering potential to address the shortage of donor corneas. To meet the functional requirements of artificial corneas in tissue engineering, it is crucial to fabricate biomimetic structures with high optical transparency using 3D printing techniques. As fiber alignment during the printing process has a pronounced impact on light transmittance, precise control of the printing parameters is essential. This study focuses on the experimental optimization of 3D printing conditions for hydrogel materials to improve their physical properties, particularly optical clarity, thereby enhancing their suitability for artificial corneal applications. Collagen derived from bovine Achilles tendons was chosen due to its excellent printability. A series of controlled experiments were conducted to systematically investigate the influence of key process parameters on hydrogel transparency. The findings enabled the identification of an optimized parameter set that significantly improved the optical properties of the 3D-printed biomimetic corneal stroma. Additionally, cell seeding and culture assays confirmed the favorable biocompatibility of the developed material.

High-resolution biofabrication requires precise microscale deposition, yet drop-on-demand (DOD) inkjet bioprinting is constrained by a narrow printable viscosity window. Many biocompatible hydrogel precursors display high zero-shear viscosity and strong shear-thinning, so stable droplet ejection typically requires dilution or reformulation that can compromise the biochemical microenvironment. We present a transient shear-enabled jetting method that exploits intrinsic shear-thinning by using a high-frequency electromagnetic microvalve to deliver short, high-pressure pulses. The resulting localized shear dynamically lowers apparent viscosity in the nozzle region and promotes controlled nucleation, ligament formation, necking, and pinch-off. A coupled, rheology-informed modeling framework (axisymmetric transient CFD, valve dynamics, and electromagnetic FEM) links actuation parameters to droplet volume and stability and guides hardware optimization. Experiments with 2.5% (w/v) sodium alginate validate stable droplet generation and tunable droplet size via stroke length and driving conditions. These results define a practical process window for high-resolution droplet printing of high-viscosity shear-thinning hydrogel inks.