Intranet

Additive Manufacturing: Layer-by-Layer Precision for Complex Designs

In regenerative medicine, additive manufacturing (AM) is a fabrication process that builds structures layer by layer, allowing precise control over material placement to produce complex, customized designs. While 3D printing is often used interchangeably, AM is a broader term that encompasses various techniques beyond extrusion-based printing.

Multiple AM Techniques

In InterLynk, AM integrates multiple techniques - including extrusion, photocuring, and Melt Electro Writing (MEW) - to construct multimaterial scaffolds with properties tailored for tissue-specific regeneration. Instead of relying on a single fabrication method, different biomaterials are processed in ways that optimize their structural and biological integration.

Virtual Modeling for Precision Fabrication

InterLynk employs advanced virtual modeling tools to optimize scaffold design before fabrication, ensuring structures that closely mimic natural tissues. These tools allow for:

  • Patient-specific modeling

    from medical imaging (MRI, CT scans).

  • Multi-physics simulations

    to fine-tune material interactions during printing.

  • Mechanical simulations

    to predict scaffold performance under physiological conditions.

Upgrading Additive Manufacturing for InterLynk Inks

To enable the printing of InterLynk’s cutting-edge personalized bio-inks, existing AM systems are being upgraded with:

1
PHOTOCURING MODULES

A specialized extrusion-based AM system with built-in light curing at the dispensing nozzle, allowing for immediate solidification of photosensitive materials. This Print and Cure technology, developed in collaboration with InterLynk partner EnvisionTEC, enhances precision and stability in bioprinting by combining printing and curing in a single step.

2
HYBRID PRINTING AND ELECTROSPINNING INTEGRATION

The system can combine extrusion-based AM with Melt Electro Writing (MEW) in a single part, enabling hierarchical structures with enhanced mechanical properties​.

3
ADVANCED MULTI-PHYSICS CONTROL SYSTEM

A computational framework optimizing printing speed, light intensity, and material interactions to improve structural integrity and biomaterial integration

Melt Electro Writing (MEW): Adding Fine Structural Control

MEW is an advanced electrospinning technique that produces ultrafine polymer fibers with micron-scale precision. In InterLynk, MEW is used to:

  • Reinforce soft tissue scaffolds with fibrous networks mimicking natural extracellular matrices.
  • Improve mechanical strength in load-bearing regions without compromising flexibility.
  • Enable better cell adhesion and integration with native tissues​.

Bridging the Gap Between Soft and Hard Tissues

A major challenge in regenerative medicine is seamlessly connecting soft and hard tissue interfaces. InterLynk’s multimaterial AM strategy overcomes this by:

  • Using MEW fibers for soft tissue-mimicking regions.
  • Integrating calcium phosphate (CaP) and polymer-based inks for bone-like structures.
  • Developing layer-by-layer assembly techniques to create a gradient transition between materials, mimicking the natural organization of multi-tissue systems like the temporomandibular joint.