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This study aims to evaluate in situ oxidative polymerization of aniline (Ani) as a post-processing method to promote extrusion-based 3D printed parts, made from insulating polymers, to components with functional properties, including electrical conductivity and chemical sensitivity.

Extrusion-based 3D printed parts of polyethylene terephthalate modified with glycol (PETG) and polypropylene (PP) were coated in an aqueous acid solution via in situ oxidative polymerization of Ani. First, the feedstocks were characterized. Densely printed samples were then used to assess the adhesion of polyaniline (PAni) and electrical conductivity on printed parts. The best feedstock candidate for PAni coating was selected for further analysis. Last, a Taguchi methodology was used to evaluate the influence of printing parameters on the coating of porous samples. Analysis of variance and Tukey post hoc test were used to identify the best levels for each parameter.

Colorimetry measurements showed significant color shifts in PP samples and no shifts in PETG samples upon pullout testing. The incorporation of PAni content and electrical conductivity were, respectively, 41% and 571% higher for PETG in comparison to PP. Upon coating, the surface energy of both materials decreased. Additionally, the dynamic mechanical analysis test showed minimal influence of PAni over the dynamic mechanical properties of PETG. The parametric study indicated that only layer thickness and infill pattern had a significant influence on PAni incorporation and electrical conductivity of coated porous samples.

Current literature reports difficulties in incorporating PAni without affecting dimensional precision and feedstock stability. In situ, oxidative polymerization of Ani could overcome these limitations. However, its use as a functional post-processing of extrusion-based printed parts is a novelty.

This study aims to design and implement a multimaterial system for printing multifunctional specimens suitable for various sectors, with a particular focus on biomedical applications such as addressing mandibular bone loss.

To enhance both the mechanical and biological properties of scaffolds, an automatic multimaterial setup using vat photopolymerization was developed. This setup features a linear system with two resin vats and one ultrasonic cleaning tank, facilitating the integration of diverse materials and structures to optimize scaffold composition. Such versatility allows for the simultaneous achievement of various characteristics in scaffold design.

The printed multimaterial scaffolds, featuring 20 Wt.% hydroxylapatite (HA) on the interior and poly-L-lactic acid (PLLA) with 1 Wt.% graphene oxide (GO) on the exterior, exhibited favorable mechanical and biological properties at the optimum postcuring and heat-treatment time. Using an edited triply periodic minimal surface (TPMS) lattice structure further enhanced these properties. Various multimaterial specimens were successfully printed and evaluated, showcasing the capability of the setup to ensure functionality, cleanliness and adequate interface bonding. Additionally, a novel Gyroid TPMS scaffold with a nominal porosity of 50% was developed and experimentally validated.

This study demonstrates the successful fabrication of multimaterial components with minimal contaminations and suitable mechanical and biological properties. By combining PLLA-HA and PLLA-GO, this innovative technique holds significant promise for enhancing the effectiveness of regenerative procedures, particularly in the realm of dentistry.