Three-Dimensional PEG Hydrogel Construct Fabrication using Stereolithography

Layered manufacturing (LM) using stereolithography (SL) of aqueous polymer solutions was accomplished so three-dimensional (3D) tissue engineered scaffolds with complex distributions of bioactive agents could be produced. Successful LM with embedded channel architectures required investigation of hydrogel thickness or cure depth as a function of photoinitiator type and concentration, energy dosage, and polymer concentration in solution. Poly(ethylene glycol) dimethacrylate (PEG-dma) with an average molecular weight of 1000 in quantities of 20% and 30% (w/v) was prepared in distilled water. Different concentrations of two photoinitiators (PIs), Sarcure1121 (2-hydroxy-2-methyl-1-phenyl-1-propanone) and Irgacure 2959 (2-hydroxy-1-[4-(2-hydroxyethoxy)phenyl]-2-methyl-1-propanone), were used to vary gel thickness at select energy dosages by controlling the scan speed of the SL machine's ultraviolet scanning system. Gel thickness was a strong function of PI type and concentration, energy dosage, and PEG-dma concentration, especially at the low PI concentrations required for implantation. The gel thickness curves were utilized to demonstrate LM for two construct geometries where different layer thicknesses were required to successfully fabricate the constructs. This work demonstrates the effective use of SL as a processing technique for complex 3D tissue scaffolds and addresses some practical considerations associated with the use of hydrogels in LM.