3D printing technology, which greatly simplifies the manufacturing of complex parts by a two-dimensional layer-upon-layer process, has flourished in recent years. As one of the most advanced technology, polymer powder 3D printing has many advantages such as high materials utilization rate, free of support structure, great design freedom, and large available materials, which has shown great potential and prospects in various industry applications. With the launch of the Multi jet Fusion system from HP, polymer powder 3D printing has been attracting more attention from industries and researchers. In this work, a comprehensive review of the main polymer powder-based 3D printing methods including binder jetting, selective laser sintering, high-speed sintering were carried out. Their forming mechanism, advantages and drawbacks, materials, and developments were presented, compared, and discussed respectively. In addition, this paper also gives suggestions on the process selection by comparing typical equipment parameters and features of each technology.

Human long bones exhibit pore size gradients with small pores in the exterior cortical bone and large pores in the interior cancellous bone. However, most current bone tissue engineering (BTE) scaffolds only have homogeneous porous structures that do not resemble the graded architectures of natural bones. Pore-size graded (PSG) scaffolds are attractive for BTE since they can provide biomimicking porous structures that may lead to enhanced bone tissue regeneration. In this study, uniform pore size scaffolds and PSG scaffolds were designed using the gyroid unit of triply periodic minimal surface (TPMS), with small pores (400 μm) in the periphery and large pores (400, 600, 800 or 1000 μm) in the center of BTE scaffolds (designated as 400-400, 400–600, 400–800, and 400–1000 scaffold, respectively). All scaffolds maintained the same porosity of 70 vol%. BTE scaffolds were subsequently fabricated through digital light processing (DLP) 3D printing with the use of biphasic calcium phosphate (BCP). The results showed that DLP 3D printing could produce PSG BCP scaffolds with high fidelity. The PSG BCP scaffolds possessed improved biocompatibility and mass transport properties as compared to uniform pore size BCP scaffolds. In particular, the 400–800 PSG scaffolds promoted osteogenesis in vitro and enhanced new bone formation and vascularization in vivo while they displayed favorable compressive properties and permeability. This study has revealed the importance of structural design and optimization of BTE scaffolds for achieving balanced mechanical, mass transport and biological performance for bone regeneration.

Four types of biomimicking radially graded scaffolds were designed and fabricated via digital light processing 3D printing. Graded gyroid–gyroid scaffolds exhibited better dimensional accuracy, compressive property, and cell proliferation rate.

The emergence of tissue engineering (TE) has provided new vital means for human body tissue/organ repair. TE scaffolds can provide temporary structural support for cell attachment, growth, and proliferation, until the body restores the mechanical and biological properties of the host tissues. Since native tissues are inhomogeneous and in many situations are graded structures for performing their unique functions, graded scaffolds have become increasingly attractive for regenerating particular types of tissues, which aim to offer a more accurate replication of native interactions and functions. Importantly, the advances introduced by additive manufacturing (AM) have now enabled more design freedom and are capable of tailoring both structural and compositional gradients within a single scaffold. In this context, graded TE scaffolds fabricated by AM technologies have been attracting increasing attention. In this review, we start with an introduction of common graded structures in the human body and analyse the advantages and strengths of AM-formed graded scaffolds. Various AM technologies that can be leveraged to produce graded scaffolds are then reviewed based on non-cellular 3D printing and cell-laden 3D bioprinting. The comparisons among various AM technologies for fabricating graded scaffolds are presented. Subsequently, we propose several types of gradients, structural, material, biomolecular and multi-gradients for scaffolds, and highlight the design methods, resulting mechanical properties and biological responses. Finally, current status, challenges and perspectives for AM in developing graded scaffolds are exhibited and discussed.

Human physical and mental health are significantly impacted by maxillofacial alveolar bone defects. The emergence of additive manufacturing metamaterial scaffolds provides a new treatment strategy for this. Due to the complexity of the jawbone and the difficulty in preparing bionic hierarchical gradient scaffolds, most current research focuses on human long bones. This study first proposes a metamaterial scaffold that simulates the jawbone. The stratified scaffolds (G300–600, G300–750,G300–900) adopt the Gyroid structure of the triply periodic minimum surfaces, with the upper and lower layers respectively simulating the cortical bone and cancellous bone of the jawbone. And a large-aperture uniform scaffold (G750) was designed as a control. And it is prepared through digital light processing 3D printing technology. The results show that sintering the scaffold to 1170 °C and holding it for 48 h can improve the mechanical properties and biocompatibility of the scaffold, making it match. G300–600 not only improves in vitro neovascularization and new bone formation, but also features a high level of compressive strength (9.86 MPa) and outstanding degradability. This gradient metamaterial scaffold has a structure, mechanical properties and biological activity that conform to the jawbone, providing a new strategy for bone defects in the maxillofacial region.