Numerical simulation and printability analysis of fused deposition modeling with dual-temperature control

Ideal tissue engineering scaffolds need interconnected pores and high porosity to enable cell survival, migration, proliferation, and differentiation. However, obtaining a high-resolution structure is difficult with traditional one-temperature control fused deposition modeling (FDM). In this study, we propose a dual-temperature control method to improve printability. A numerical model is developed in which the viscosity is a function of temperature and shear rate to study the influence of two different temperature control modes. Quantitative tests are used to assess filament formation and shape fidelity, including one-dimensional filament printing, deposition at corners, fusion, and collapse. By using dual-temperature control, the width of the deposited poly(ε-caprolactone) filament is reduced to 50 μm. The comparative results of both the experimental method and numerical simulation suggest that the dual-temperature control FDM can manufacture spatially arranged constructs and presents a promising application in tissue engineering. Graphic abstract