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<p>The advancement of additive manufacturing (AM) technologies offers transformative potential in the fabrication of custom bioreactors for therapeutic bioproduction. This study systematically evaluates a selection of materials and AM technologies to guide their application in bioreactor development. Emphasis is placed on Material Extrusion () and specifically Arburg Plastic Freeforming (APF), which enables the use of industrial-grade polymers not traditionally optimized for AM, including polylactic acid (), polyhydroxy acid (), copolyesters, polycarbonate (), Homo-Polypropylene (), and linear low-density polyethylene (). Comparative assessments were conducted using four AM technologies—APF, fused deposition modelling (FDM), stereolithography (SLA), and PolyJet—across parameters including printability, mechanical integrity, surface roughness, dimensional stability post-autoclaving, and cytotoxicity. Performance was quantified using differential scanning calorimetry (), 3D scanning, electronic microscopy, 3D profilometry, and fibroblast growth assays. A scoring model incorporating biological, structural, and regulatory criteria was developed to identify optimal material-technology pairings. Results indicate that the following brands Makrolon<sup>®</sup> Rx 2430 (APF), AllPHA (FDM), and Durable (SLA) offer the most promising combinations for AM-based bioreactor fabrication. This work provides a technical framework for selecting materials and processes tailored to specific application needs, facilitating the on-demand production of robust and biocompatible bioreactors.</p>

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Material technical guide for on-demand additive manufacturing production of bioreactors

  • 期刊论文

  • 发表日期：

    2026年1月12日

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  • Christophe A. Marquette,
  • Matthieu Koprivnik,
  • Julien Le Boterff,
  • Lucas Lemarié,
  • Edwin-Joffrey Courtial,
  • Valernst Martial Gilmus,
  • Celine Thomann,
  • Lukas Raddatz,
  • Magali Barbaroux,
  • Emma Petiot

摘要

The advancement of additive manufacturing (AM) technologies offers transformative potential in the fabrication of custom bioreactors for therapeutic bioproduction. This study systematically evaluates a selection of materials and AM technologies to guide their application in bioreactor development. Emphasis is placed on Material Extrusion () and specifically Arburg Plastic Freeforming (APF), which enables the use of industrial-grade polymers not traditionally optimized for AM, including polylactic acid (), polyhydroxy acid (), copolyesters, polycarbonate (), Homo-Polypropylene (), and linear low-density polyethylene (). Comparative assessments were conducted using four AM technologies—APF, fused deposition modelling (FDM), stereolithography (SLA), and PolyJet—across parameters including printability, mechanical integrity, surface roughness, dimensional stability post-autoclaving, and cytotoxicity. Performance was quantified using differential scanning calorimetry (), 3D scanning, electronic microscopy, 3D profilometry, and fibroblast growth assays. A scoring model incorporating biological, structural, and regulatory criteria was developed to identify optimal material-technology pairings. Results indicate that the following brands Makrolon® Rx 2430 (APF), AllPHA (FDM), and Durable (SLA) offer the most promising combinations for AM-based bioreactor fabrication. This work provides a technical framework for selecting materials and processes tailored to specific application needs, facilitating the on-demand production of robust and biocompatible bioreactors.