Algorithmic Linearization Improves Syringe-based Extrusion in Elastic Systems Using Hydrogel-based Materials

Accuracy and precision are essential in extrusion-based material handling such as three-dimensional (3D) bioprinting. However, the elasticity of components, backlash, variability of nozzle and cartridge shapes, etc. can lead to unpredictable printing results, which is further complicated by the wide range of rheologically diverse materials and complex sample designs.To address this issue, we present an algorithmic approach to compensate for the discrepancies between piston motion and material extrusion in syringe-based extrusion systems. This approach relies on cyclical, iterative optimization through rapid piston movements, which are adjusted based on extrusion analysis.In this work we establish a general theoretical framework for extrusion and link the rheological properties of prepared hydrogels with shear rates in a typical bioprinting process. The determined properties are compared with the success of the developed algorithm to modify machine instructions for precise material deposition of short, interrupted lines, as well as multi-layered scaffold structures.Overall, our approach provides a means of improving the accuracy and precision of complex extrusion-based bioprinting systems, without prior knowledge of set-up or material properties, making it highly versatile and suitable for a wide range of applications, particularly when the combined set-up and material properties are too complex for solely predictive approaches.