The domains of biomedical engineering and biosensors have been revolutionized by additive manufacturing, commonly referred to as 3D printing. This study delves into the various ways additive printing has been used in these fields, showcasing its role in creating biosensor parts, implants, tissue engineering scaffolds, and medical equipment. The production of typical prosthetics and implants has been revolutionized by additive manufacturing. It allows for the manufacture of complicated geometries with a high degree of precision and personalization, which in turn improves clinical results and patient care. Additionally, innovative diagnostic tools have been developed through the combination of biosensor technologies with additive manufacturing. These tools can identify infections, physiological factors, and biomarkers with a level of sensitivity and specificity that has never been seen before. This review discusses the present and prospects of additive manufacturing for biomedical and biosensor applications, as well as the state-of-the-art techniques and materials used in this sector. It also analyzes the ongoing obstacles in this area. Additive manufacturing has enormous potential to transform bio sensing technology and healthcare delivery, opening the door to novel approaches to difficult medical problems.
da SilvaLRRSalesWFCamposFDAR, et al. A comprehensive review on additive manufacturing of medical devices. Prog Addit Manuf2021; 6(3): 517–553.
2.
YuCSchimelmanJWangP, et al. Photopolymerizable biomaterials and light-based 3D printing strategies for biomedical applications. Chem Rev2020; 120(19): 10695–10743.
3.
MandonCABlumLJMarquetteCA.Adding biomolecular recognition capability to 3D printed objects. Anal Chem2016; 88(21): 10767–10772.
MajeedAAhmedALvJ, et al. A state-of-the-art review on energy consumption and quality characteristics in metal additive manufacturing processes. J Braz Soc Mech Sci Eng2020; 42: 1–25.
6.
KrujatzFLodeASeidelJ, et al. Additive Biotech—chances, challenges, and recent applications of additive manufacturing technologies in biotechnology. New Biotechnol2017; 39: 222–231.
7.
ZhuWMaXGouM, et al. 3D printing of functional biomaterials for tissue engineering. Curr Opin Biotechnol2016; 40: 103–112.
8.
WangYAhmedAAzamA, et al. Applications of additive manufacturing (AM) in sustainable energy generation and battle against COVID-19 pandemic: the knowledge evolution of 3D printing. J Manuf Syst2021; 60: 709–733.
9.
KumarRKumarMChohanJS.The role of additive manufacturing for biomedical applications: a critical review. J Manuf Process2021; 64: 828–850.
10.
LiuYWangWZhangLC.Additive manufacturing techniques and their biomedical applications. Fam Med Community Health2017; 5(4): 286–298.
11.
LiuYJWangHLLiSJ, et al. Compressive and fatigue behavior of beta-type titanium porous structures fabricated by electron beam melting. Acta Mater2017; 126: 58–66.
12.
TareqMSRahmanTHossainM, et al. Additive manufacturing and the COVID-19 challenges: an in-depth study. J Manuf Syst2021; 60: 787–798.
13.
TarfaouiMNachtaneMGodaI, et al. 3D printing to support the shortage in personal protective equipment caused by COVID-19 pandemic. Materials2020; 13(15): 3339.
PengTLvJMajeedA, et al. An experimental investigation on energy-effective additive manufacturing of aluminum parts via process parameter selection. J Clean Prod2021; 279: 123609.
16.
ZadpoorAA.Design for additive bio-manufacturing: from patient-specific medical devices to rationally designed meta-biomaterials. Int J Mol Sci2017; 18(8): 1607.
17.
HuQSunXZParmenterCDJ, et al. Additive manufacture of complex 3D Au-containing nanocomposites by simultaneous two-photon polymerisation and photoreduction. Sci Rep2017; 7(1): 17150.
18.
McHughKJNguyenTDLinehanAR, et al. Fabrication of fillable microparticles and other complex 3D microstructures. Science2017; 357(6356): 1138–1142.
19.
HullCW.Apparatus for production of three-dimensional objects by stereolithography. United States Patent. 1984.
20.
NormanJMaduraweRDMooreCM, et al. A new chapter in pharmaceutical manufacturing: 3D-printed drug products. Adv Drug Deliv Rev2017; 108: 39–50.
21.
AhangarPAkouryERamirez Garcia LunaAS, et al. Nanoporous 3D-printed scaffolds for local doxorubicin delivery in bone metastases secondary to prostate cancer. Materials2018; 11(9): 1485.
22.
AkouryEWeberMHRosenzweigDH.3D-Printed nanoporous scaffolds impregnated with zoledronate for the treatment of spinal bone metastases. MRS Adv2019; 4(21): 1245–1251.
23.
CoelhoGChavesTMGoesAF, et al. Multimaterial 3D printing preoperative planning for frontoethmoidal meningoencephalocele surgery. Childs Nerv Syst2018; 34: 749–756.
24.
ArabnejadSJohnstonBTanzerM, et al. Fully porous 3D printed titanium femoral stem to reduce stress-shielding following total hip arthroplasty. J Orthop Res2017; 35(8): 1774–1783.
25.
YangCWangXMaB, et al. 3D-printed bioactive Ca3SiO5 bone cement scaffolds with nano surface structure for bone regeneration. ACS Appl Mater Interfaces2017; 9(7): 5757–5767.
26.
MarshallSLJacobsenTDEmsboE, et al. Three-dimensional-printed flexible scaffolds have tunable biomimetic mechanical properties for intervertebral disc tissue engineering. ACS Biomater Sci Eng2021; 7(12): 5836–5849.
27.
FairagRRosenzweigDHRamirez-GarcialunaJL, et al. Three-dimensional printed polylactic acid scaffolds promote bone-like matrix deposition in vitro. ACS Appl Mater Interfaces2019; 11(17): 15306–15315.
28.
Vikram SinghAHasan Dad AnsariMWangS, et al. The adoption of three-dimensional additive manufacturing from biomedical material design to 3D organ printing. Appl Sci2019; 9(4): 811.
29.
MansuriyaBDAltintasZ.Applications of graphene quantum dots in biomedical sensors. Sensors2020; 20(4): 1072.
30.
ReyesDRIossifidisDAurouxPA, et al. Micro total analysis systems. 1. Introduction, theory, and technology. Anal Chem2002; 74(12): 2623–2636.
31.
AliMAHuCYttriEA, et al. Recent advances in 3D printing of biomedical sensing devices. Adv Funct Mater2022; 32(9): 2107671.
32.
BeebeDJMensingGAWalkerGM.Physics and applications of microfluidics in biology. Annu Rev Biomed Eng2002; 4(1): 261–286.
33.
DuffyDCMcDonaldJCSchuellerOJ, et al. Rapid prototyping of microfluidic systems in poly(dimethylsiloxane). Anal Chem1998; 70(23): 4974–4984.
34.
LambertiAMarassoSLCocuzzaM.PDMS membranes with tunable gas permeability for microfluidic applications. RSC Adv2014; 4(106): 61415–61419.
35.
MarkovDALillieEMGarbettSP, et al. Variation in diffusion of gases through PDMS due to plasma surface treatment and storage conditions. Biomed Microdevices2014; 16: 91–96.
36.
RajMKChakrabortyS.PDMS microfluidics: a mini review. J Appl Polym Sci2020; 137(27): 48958.
37.
Monserrat LopezDRottmannPFusseneggerM, et al. Silicon-based 3D microfluidics for parallelization of droplet generation. Micromachines2023; 14(7): 1289.
38.
PalmaraGFrascellaFRoppoloI, et al. Functional 3D printing: Approaches and bioapplications. Biosens Bioelectron2021; 175: 112849.
39.
JammalamadakaUTappaK.Recent advances in biomaterials for 3D printing and tissue engineering. J Funct Biomater2018; 9(1): 22.
40.
BeckerH.Hype, hope and hubris: the quest for the killer application in microfluidics. Lab Chip2009; 9(15): 2119–2122.
41.
JiMLiFLiJ, et al. Enhanced mechanical properties, water resistance, thermal stability, and biodegradation of the starch-sisal fibre composites with various fillers. Mater Des2021; 198: 109373.
42.
MurrLEGaytanSMMedinaF, et al. Next-generation biomedical implants using additive manufacturing of complex, cellular and functional mesh arrays. Philos Trans R Soc A2010; 368(1917): 1999–2032.
43.
VaeziMSeitzHYangS.A review on 3D micro-additive manufacturing technologies. Int J Adv Manuf Technol2013; 67: 1721–1754.
44.
SinghRPPandeyPM. Comparison of conventional and ultrasonic drilling on cutting force in porcine and human femur. In: International manufacturing science and engineering conference, 3 September 2020, Vol. 84256, p.V001T03A012. American Society of Mechanical Engineers.
45.
SinghRPPandeyPMMirMA, et al. Thermal changes during drilling in human femur by rotary ultrasonic bone drilling machine: A histologic and ultrastructural study. J Biomed Mater Res B Appl Biomater2022; 110(5): 1023–1033.
46.
TackPVictorJGemmelP, et al. 3D-printing techniques in a medical setting: a systematic literature review. Biomed Eng Online2016; 15(1): 21.
47.
KesslerAHickelRReymusM.3D printing in dentistry-state of the art. Oper Dent2020; 45(1): 30–40.
48.
KangHWLeeSJKoIK, et al. A 3D bioprinting system to produce human-scale tissue constructs with structural integrity. Nat Biotechnol2016; 34(3): 312–319.
49.
AgarwalRSinghRPGuptaV, et al. Influence of cutting force on temperature, microcracks and chip morphology during rotary ultrasonic bone drilling: an in-vitro study. J Braz Soc Mech Sci Eng2022; 44(7): 301.
50.
CuboNGarciaMDel CañizoJF, et al. 3D bioprinting of functional human skin: production and in vivo analysis. Biofabrication2016; 9(1): 015006.
51.
GaoGHubbellKSchillingAF, et al. Bioprinting cartilage tissue from mesenchymal stem cells and PEG hydrogel. In: 3D cell culture: methods and protocols. Springer New York, New York, NY, 2017, pp.391–398.
52.
SinghRPPandeyPMMridhaAR.An in-vitro study of temperature rise during rotary ultrasonic bone drilling of human bone. Med Eng Phys2020; 79: 33–43.
53.
GuptaVSinghRPPandeyPM, et al. In vitro comparison of conventional surgical and rotary ultrasonic bone drilling techniques. Proc IMechE, Part H: J Engineering in Medicine2020; 234(4): 398–411.
54.
AliMARajabiMSudhir SaliS.Additive manufacturing potential for medical devices and technology. Curr Opin Chem Eng2020; 28: 127–133.
55.
FrancisMPKemperNMaghdouri-WhiteY, et al. Additive manufacturing for biofabricated medical device applications. In: Additive manufacturing. Butterworth-Heinemann, 2018, pp.311–344.
56.
Mohan PandeyPVenkata ReddyNDhandeSG. Slicing procedures in layered manufacturing: a review. Rapid Prototyp J2003; 9(5): 274–288.
57.
KumarPAhujaIPSSinghR.Application of fusion deposition modelling for rapid investment casting - a review. Int J Mater Eng Innov2012; 3(3–4): 204–227.
58.
BoparaiKSSinghRSinghH.Development of rapid tooling using fused deposition modeling: a review. Rapid Prototyp J2016; 22(2): 281–299.
59.
HanTKunduSNagA, et al. 3D printed sensors for biomedical applications: a review. Sensors2019; 19(7): 1706.
60.
MahindruDVMahendruPMahindruV, et al. Review of rapid prototyping-technology for the future. Glob J Comput Sci Technol2013; 13(4): 26–38.
61.
BhargavASanjairajVRosaV, et al. Applications of additive manufacturing in dentistry: a review. J Biomed Mater Res B Appl Biomater2018; 106(5): 2058–2064.
62.
VashishthaVKMakadeRMehlaN.Advancement of rapid prototyping in aerospace industry-a review. Int J Eng Sci Technol2011; 3(3): 2486–2493.
63.
BarcliftMWWilliamsCB.Examining variability in the mechanical properties of parts manufactured via polyjet direct 3D printing. J Mater Sci2023; 58(6): 2459–2465.
64.
IonitaCNMokinMVarbleN, et al. Challenges and limitations of patient-specific vascular phantom fabrication using 3D Polyjet printing. In: Medical imaging 2014: biomedical applications in molecular, structural, and functional imaging, 2014, Vol. 9038, pp.164–175. SPIE.
65.
OlakanmiEOCochraneRFDalgarnoKW.A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: processing, microstructure, and properties. Prog Mater Sci2015; 74: 401–477.
66.
KumarS.Selective laser sintering: a qualitative and objective approach. JOM2003; 55: 43–47.
67.
AgarwalaMBourellDBeamanJ, et al. Direct selective laser sintering of metals. Rapid Prototyp J1995; 1(1): 26–36.
68.
FrazierWE.Metal additive manufacturing: a review. J Mater Eng Perform2014; 23: 1917–1928.
69.
NakamuraMKobayashiATakagiF, et al. Biocompatible inkjet printing technique for designed seeding of individual living cells. Tissue Eng2005; 11(11–12): 1658–1666.
70.
HornbeckLJ. Digital light processing for high-brightness high-resolution applications. In: Projection Displays III. SPIE, 1997, pp.27–40, Vol. 3013.
71.
DaFGaiS.Flexible three-dimensional measurement technique based on a digital light processing projector. Appl Opt2008; 47(3): 377–385.
72.
ChimeneDMillerLCrossLM, et al. Nanoengineered osteoinductive bioink for 3D bioprinting bone tissue. ACS Appl Mater Interfaces2020; 12(14): 15976–15988.
73.
KimJChoiHSKimYM, et al. Thermo-responsive nanocomposite bioink with growth-factor holding and its application to bone regeneration. Small2023; 19: 2203464.
74.
KimGJKimLKwonOS.Application of 3D bioprinting technology for tissue regeneration, drug evaluation, and drug delivery. Appl Sci Converg Technol2023; 32(1): 1–6.
75.
PuriASahaiNAhmedT, et al. 3D bioprinting for diagnostic and therapeutic application. Mater Today Proc2023; 17.
76.
BaranwalJBarseBFaisA, et al. Biopolymer: a sustainable material for food and medical applications. Polymers2022; 14: 983.
77.
FarokhiMMottaghitalabFReisRL, et al. Functionalized silk fibroin nanofibers as drug carriers: advantages and challenges. J Control Release2020; 321: 324–347.
78.
MaharjanBParkJKaliannagounderVK, et al. Regenerated cellulose nanofiber reinforced chitosan hydrogel scaffolds for bone tissue engineering. Carbohydr Polym2021; 251: 117023.
79.
SaadiMASRMaguireAPottackalNT, et al. Direct ink writing: a 3D printing technology for diverse materials. Adv Mater2022; 34(28): 2108855.
80.
VyasABandhu GhoshSBandyopadhyay-GhoshS, et al. Digital light processing mediated 3D printing of biocomposite bone scaffolds: physico-chemical interactions and in-vitro biocompatibility. Polym Compos2022; 43(5): 3175–3188.
81.
HerathBSureshSDowningD, et al. Mechanical and geometrical study of 3D printed Voronoi scaffold design for large bone defects. Mater Des2021; 212: 110224.
YanQDongHSuJ, et al. A review of 3D printing technology for medical applications. Eng2018; 4(5): 729–742.
84.
AcquahS. Carbon nanotubes and graphene as additives in 3D printing. Carbon nanotubes-current progress of their polymer composites. 2016, pp. 227–251.
85.
YuWZhouHLiBQ, et al. 3D printing of carbon nanotubes-based microsupercapacitors. ACS Appl Mater Interfaces2017; 9(5): 4597–4604.
86.
GladmanASMatsumotoEANuzzoRG, et al. Biomimetic 4D printing. Nat Mater2016; 15(4): 413–418.
87.
TeohJEMAnJChuaCK, et al. Hierarchically self-morphing structure through 4D printing. Virtual Phys Prototyp2017; 12(1): 61–68.
88.
ArcadioFAliWBencivengaD, et al. 3D-printed biosensors in biomedical applications exploiting plasmonic phenomena and antibody self-assembled monolayers. Biomed Opt Express2024; 15(3): 1976–1994.
89.
ChowdhuryPLawranceRLuZY, et al. Recent progress in dual/multi-modal detection modes for improving sensitivity and specificity of lateral flow immunoassays applied for point-of-care diagnostics. TrAC Trends Anal Chem2024; 177: 117798.
90.
PadashMEnzCCarraraS.Microfluidics by additive manufacturing for wearable biosensors: a review. Sensors2020; 20(15): 4236.
91.
MiaoSZhuWCastroNJ, et al. 4D printing smart biomedical scaffolds with novel soybean oil epoxidized acrylate. Sci Rep2016; 6: 27226.
92.
YinKDingXXuZ, et al. Multiplexed colorimetric detection of SARS-CoV-2 and other pathogens in wastewater on a 3D printed integrated microfluidic chip. Sens Actuators B Chem2021; 344: 130242.
93.
GideonOSamuelHSOkinoIA.Biocompatible materials for next-generation biosensors. Discov Chem2024; 1(1): 34.
MishraASinghPKChauhanN, et al. Emergence of integrated biosensing-enabled digital healthcare devices. Sens Diagn2024; 3(5): 718–744.
96.
ChenHLukKM.Detection capability enhanced biosensor antenna for portable electromagnetic stroke diagnostic systems. IEEE Trans Biomed Circuits Syst2024; 18(1): 145–159.
97.
YangCWangZXiaoK, et al. Portable optical fiber biosensors integrated with smartphone: technologies, applications, and challenges. Biomed Opt Express2024; 15(3): 1630–1650.
98.
ZhuWWebsterTJZhangLG.4D printing smart biosystems for nanomedicine. Nanomed2019; 14(13): 1643–1645.
99.
ZhangXLiLOuyangJ, et al. Electroactive electrospun nanofibers for tissue engineering. Nano Today2021; 39: 101196.
100.
KrishnanSKNatarajNMeyyappanM, et al. Graphene-based field-effect transistors in biosensing and neural interfacing applications: recent advances and prospects. Anal Chem2023; 95(5): 2590–2622.
101.
DuJShiFWangK, et al. Metal-organic framework-based biosensing platforms for diagnosis of bacteria-induced infectious diseases. TrAC Trends Anal Chem2024; 175: 117707.
102.
FlynnCDChangD.Artificial intelligence in point-of-care biosensing: challenges and opportunities. Diagnostics2024; 14(11): 1100.
103.
de SouzaAFerreiraPde JesusI, et al. Sustainability, sustainable development, sustainable chemistry, and green chemistry: parallels and interconnections. Quim Nova2024; 47(9): e20240049.
104.
SharmaAFaberHKhoslaA, et al. 3D printed electrochemical devices for bio-chemical sensing: a review. Mater Sci Eng R Rep2023; 156: 100754.
105.
GeQDunnCKQiHJ, et al. Active origami by 4D printing. Smart Mater Struct2014; 23(9): 094007.
106.
MandonCABlumLJMarquetteCA.3D–4D printed objects: new bioactive material opportunities. Micromachines2017; 8(4): 102.
107.
NagAMukhopadhyaySC.Occupancy detection at smart home using real-time dynamic thresholding of flexiforce sensor. IEEE Sens J2015; 15(8): 4457–4463.
108.
ChaudharyVTahaBALuckyL, et al. Nose-on-chip nanobiosensors for early detection of lung cancer breath biomarkers. ACS Sens2024; 9(9): 4469–4494.
109.
BarsolaBSaklaniSPathaniaD, et al. Exploring bio-nanomaterials as antibiotic allies to combat antimicrobial resistance. Biofabrication2024; 16(4): 042007.
110.
SaklaniSBarsolaBPathaniaD, et al. Nanomaterials-integrated electrochemical biosensors as pioneering solutions for zoonotic disease diagnosis. J Electrochem Soc2024; 171(8): 087502.
111.
ChaudharyVRustagiSKaushikA, et al. Perspective—prospect of nano-enabled optical biosensors for antibiotic abuse surveillance as an early prevention tool for antimicrobial resistance. ECS J Solid State Sci Technol2024; 13(1): 017003.
112.
WangYXuYZhaiW, et al. In-situ growth of robust superlubricated nano-skin on electrospun nanofibers for post-operative adhesion prevention. Nat Commun2022; 13(1): 5056.
113.
ZhaoYLiuYKangS, et al. Peripheral nerve injury repair by electrical stimulation combined with graphene-based scaffolds. Front Bioeng Biotechnol2024; 12: 1345163.
114.
YangHZhengJWangW, et al. Zr-MOF carrier-enhanced dual-mode biosensing platforms for rapid and sensitive diagnosis of Mpox. Adv Sci2024; 11(38): 2405848.
115.
JiangZHanXZhaoC, et al. Recent advance in biological responsive nanomaterials for biosensing and molecular imaging application. Int J Mol Sci2022; 23(3): 1923.
