Bags used to protect and accelerate the ripening of bananas are a clear example of the environmental problem of packaging waste. Small pieces of these non-biodegradable bags are frequently disposed on the soil by accident (environmental conditions and poor handling during the harvest) and remain there for years. This work focuses on the development of protective biodegradable bags reinforced with banana fiber, obtained from waste of the banana plants, thus promoting a circular economy and a more environmentally friendly process. To achieve this, different bio-based composites were tested (processability) by compounding extrusion (biopolymer and banana fiber with different process steps) and blown film extrusion. The bags produced were tested in field and sequentially improved in three generations of biofilms. The results showed that the maximum processable fiber content was 5 wt %. Additionally, the micronizing of the compounds was crucial to simplify the blown film extrusion and improve the smoothness of the bags (scratches avoidance on the banana surface). The final bags (Mater-Bi biopolymer, 5% combed and sieved banana fiber, and 2.5 wt % TiO₂ for ultraviolet light filtration), performed better than the conventional ones (faster maturing, i.e., earlier harvest, and easier handling) and fulfilled the biodegradability, composting and ecotoxicity test requirements.

Porous structures are of great importance in tissue engineering. Most scaffolds are 3D printed, but there is no single methodology to model these printed parts and to apply finite element analysis to estimate their mechanical behaviour. In this work, voxel-based and geometry-based modelling methodologies are defined and compared in terms of computational efficiency, dimensional accuracy, and mechanical behaviour prediction of printed parts. After comparing the volumes and dimensions of the models with the theoretical and experimental ones, they are more similar to the theoretical values because they do not take into account dimensional variations due to the printing temperature. This also affects the prediction of the mechanical behaviour, which is not accurate compared to reality, but it makes it possible to determine which geometry is stiffer. In terms of comparison of modelling methodologies, based on process efficiency, geometry-based modelling performs better for simple or larger parts, while voxel-based modelling is more advantageous for small and complex geometries.

Additive manufacturing technology, specifically material extrusion, offers great potential for scaffold manufacturing in tissue engineering. This study presents a novel methodology for the design and optimization of 3D printed polymeric scaffolds to enhance cell viability, thereby promoting improved cell proliferation for tissue engineering applications. Different infill patterns, including gyroid, parallel sinusoidal, and symmetric sinusoidal, were evaluated to determine their impact on cell proliferation and tissue regeneration. To overcome the limitations of existing slicer software, a novel open-source software called FullControl GCode Designer was utilized, enabling the creation of customized infill patterns without restrictions. VOLCO software was employed to generate voxelized 3D models of the scaffolds, simulating the material extrusion process. Finite element analysis was conducted using Abaqus software to evaluate the mechanical properties of the different designs. Additionally, new scripts were developed to evaluate the interconnectivity and pore size of the voxelized models. A factorial design of experiments and a genetic algorithm (combined with Kriging metamodels) were applied to identify the optimal configuration based on optimization criteria (keeping the mechanical stiffness and pore size within the recommended values for trabecular bone and maximizing the surface and interconnectivity). Biological testing was conducted on polylactic acid scaffolds to preliminarily validate the effectiveness of the modeling and optimization methodologies in this regard. The results demonstrated the agreement between the optimization methodology and the biological test since the optimum in both cases was a symmetric sinusoidal pattern design with a configuration resulting in a structure with 53.08% porosity and an equivalent pore size of 584 µm. Therefore, this outcome validates the proposed methodologies, emphasizing the role of pore surface area and interconnectivity in supporting cell proliferation. Overall, this research contributes to the advancement of AM technology in tissue engineering and paves the way for further optimization studies in scaffold design.