In recent years, there has been a surge in the extrusion-based 3D printing of materials for various biomedical applications. This work presents a novel methodology for optimizing extrusion-based 3D bioprinting of a gelatin/siloxane hybrid material for biomedical applications. A systematic approach integrating rheological characterization, computational fluid dynamics simulation (CFD), and machine-learning-based image analysis, was employed. Rheological tests revealed a shear stress of 50 Pa, a maximum viscosity of 3 × 10⁵ Pa·s, a minimum viscosity of 0.089 Pa·s, and a shear rate of 15 rad/s (27G nozzle, 180 kPa pressure, 32 °C temperature, 30 mm/s velocity) for a BIO X bioprinter. While these parameters yielded constructs with 54.5% similarity to the CAD design, a multi-faceted optimization strategy was implemented to enhance fidelity, computational fluid dynamics simulations in SolidWorks, coupled with a custom-develop a binary classifier convolutional neuronal network for post-printing image analysis, facilitated targeted parameter refinement. Subsequent printing optimized parameters (25G nozzle, 170 kPa, 32 °C, 20 mm/s) achieved a significantly improved similarity of 92.35% CAD, demonstrating efficacy. The synergistic combination of simulation and machine learning ultimately enabled the fabrication of complex 3D constructs with a high fidelity of 94.13% CAD similarity, demonstrating the efficacy and potential of this integrated approach for advanced biofabrication.

This study proposes the development of a recycling process for the reintegration of dental zirconia waste into CAD/CAM systems for rapid prototyping, with the objective of demonstrating the feasibility of manufacturing functional products from recycled zirconia obtained from a commercial dental laboratory. The proposed methodology aims to explore a simple and economically viable process, which involves the purification and processing of a heterogeneous zirconia powder, followed by the fabrication of pre-sintered blocks suitable for CAD/CAM applications. The recycled bulk ceramic was characterized and compared with commercial zirconia through density measurements, X-ray diffraction, scanning electron microscopy, Vickers hardness, flexural strength testing, and sintering shrinkage analysis. The results indicated that, although recycled zirconia exhibits lower property values than the commercial reference material, it retains adequate characteristics for specific practical applications. Consequently, to demonstrate industrial feasibility, four components were designed using CAD and machined using CAM from the recycled blocks, simulating a rapid prototyping process. The fabricated components exhibited a smooth and flawless surface, were mechanically robust and solid to the touch, and showed well-defined contours with sharp edges. Dimensional analysis demonstrated high accuracy, with an average percentage error of 0.53% ± 0.14. These findings demonstrate that high-value ceramic waste can be reintegrated into the production chain as functional industrial components through a process that is closely aligned with the real conditions of industrial recycling, while also mitigating environmental contamination from hazardous industrial waste.

Achieving effective tissue integration depends mainly on the biological performance of polymeric implants. Poly-ether-ether-ketone (PEEK) is widely used as an implant material; however, its inert nature results in limited biological interactions. Various surface modification techniques have been investigated to enhance its bioactivity and overall biological performance. In this study, the PEEK surface was activated using low-pressure oxygen plasma and functionalized with phosphate and calcium ions. Comprehensive surface characterization by contact angle, scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), and Fourier Transform Infrared (FT-IR) confirmed the effect of plasma and the ionic surface incorporation. The biological response was evaluated through cell viability, adhesion, and proliferation in NIH/3T3 fibroblasts and HOS osteoblasts, and the results indicated the efficacy of the surface modifications. Therefore, the proposed treatments provide an efficient strategy to improve the biological performance of PEEK-based implants.

Inert polymeric implants must evolve to enhance their biological interactions with host tissue, triggering positive cellular responses and promoting tissue bonding and integration. Poly-ether-ether-ketone (PEEK) is widely used as an implant material; however, its inert nature results in limited biological interactions. Various surface modification techniques have been investigated to enhance its bioactivity and overall biological performance. In this study, the PEEK surface was bioactivated through a chemical treatment involving two steps: surface activation using low-pressure oxygen plasma, followed by biofunctionalization with phosphate and calcium ions. Comprehensive surface characterization by contact angle, scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), and Fourier-transform infrared (FT-IR) confirmed the effect of plasma and the ionic surface incorporation. The biological response was evaluated through cell viability, adhesion, and proliferation in NIH/3T3 fibroblasts and HOS osteoblasts, and the results indicated the efficacy of the surface modifications. Therefore, the proposed treatments provide an efficient strategy to improve the biological performance of PEEK-based implants.