Influence of Process Parameters on Shape Fidelity in Extrusion-Based Bioprinting: A Rheological Perspective

Influence of Process Parameters on Shape Fidelity in Extrusion-Based Bioprinting: A Rheological Perspective | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Influence of Process Parameters on Shape Fidelity in Extrusion-Based Bioprinting: A Rheological Perspective Carmine Borgia, David Izquierdo Rodriguez, Domenico Gabriele, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7692085/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 17 Mar, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Extrusion-based bioprinting is one of the most accessible and versatile additive manufacturing techniques for bioengineering applications, enabling the controlled deposition of a wide range of materials, including hydrogels. These soft and viscoelastic materials, composed of polymeric chains connected by physical or chemical bonds, are crucial in ensuring cell viability and proliferation, because of their ability in absorbing significant amounts of liquid. In this context, shape fidelity, defined as the degree of correspondence between the printed construct and its digital model, emerges as a critical performance metric. This study investigates the influence of key process parameters, i.e. inlet pressure, printing speed and bio-ink temperature, on shape fidelity in the extrusion bioprinting of two hydrogels: a natural alginate/cellulose blend and a synthetic polyethylene glycol-based material. Comprehensive rheological characterization, including oscillatory tests and flow curves, was performed to assess the materials’ viscoelastic behavior and shear-thinning properties. A shape fidelity index (SFI) was introduced and applied to quantify dimensional accuracy across 24 different parameter configurations. The resulting construct quality revealed clear correlations between process conditions and material rheology. The synthetic hydrogel exhibited greater stability under varying process conditions, making it easier to achieve high SFI values. In contrast, the natural hydrogel was more sensitive to the applied process parameters, showing notable instability. Nevertheless, when optimized input variables are used, the natural hydrogel can attain even higher SFI values. These findings underscore the importance of integrated rheological analysis and parameter optimization for advancing bioprinting performance and improving the fabrication of complex and high-resolution biomedical structures. Bioprinting Extrusion-based Hydrogels Shape fidelity - Rheology Full Text Cite Share Download PDF Status: Published Journal Publication published 17 Mar, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 19 Dec, 2025 Reviewers agreed at journal 22 Oct, 2025 Reviewers invited by journal 22 Oct, 2025 Editor assigned by journal 29 Sep, 2025 First submitted to journal 25 Sep, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7692085","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":533390504,"identity":"114e60f6-d056-43a1-bb38-2561b341bbfd","order_by":0,"name":"Carmine 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