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bioRxiv · 10.64898/2026.06.23.734010

A Universal Free-Degree Orientation Extrusion Head Enables Conformal and Non-Planar Bio-Additive Manufacturing toward Adaptive and Future-Ready Bioprinting

Janarthanan, G.·Chand, R.·Vijayavenkataraman, S.
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Abstract

Conventional extrusion-based 3D bioprinting encounters limitations in fabricating intricate tissue architectures due to fixed nozzle diameters and fixed deposition orientations. These constraints restrict conformal printing on curved or non-planar surfaces and often necessitate support-intensive fabrication strategies. This work introduces a mechanically simplified extrusion platform inspired by the swivel jet nozzle, featuring a free-degree-of-orientation extrusion head termed the universal extrusion head (Univ-Ex head), coupled with a modular nozzle architecture. The Univ-Ex head employs a swivel-like mechanical design that enables orientation freedom without external actuation in its current implementation, thereby minimizing mechanical complexity while supporting deposition on physiologically relevant, non-planar geometries. Multiple nozzle concepts were developed through comparative CAD iterations, with two representative geometries--a flat nozzle and a conical nozzle--selected for experimental validation. The platform is evaluated through parametric CAD design, stereolithography-printed prototypes, proof-of-concept extrusion experiments, and fluid dynamics simulations performed using FLOW-3D software. Numerical and experimental results demonstrate stable filament formation and clear diameter-dependent extrusion behavior, while simulations further confirm the feasibility of angled and non-planar deposition. A variable-diameter nozzle concept is proposed as a forward design direction to enable real-time adjustment of bioink flow rate and deposition resolution in principle; however, the present study intentionally validates the system using fixed-diameter nozzle variants to maintain stable numerical and experimental boundary conditions. A gear-integrated Univ-Ex head is also presented as a forward upgrade and demonstrated as a single-piece prototype. Collectively, this work establishes a scalable, hardware-focused pathway toward conformal bio-additive manufacturing. Graphical Abstract O_FIG O_LINKSMALLFIG WIDTH=200 HEIGHT=96 SRC="FIGDIR/small/734010v1_ufig1.gif" ALT="Figure 1"> View larger version (63K): org.highwire.dtl.DTLVardef@7a3213org.highwire.dtl.DTLVardef@6d9748org.highwire.dtl.DTLVardef@e733aforg.highwire.dtl.DTLVardef@f24a86_HPS_FORMAT_FIGEXP M_FIG C_FIG

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Janarthanan, G., Chand, R., Vijayavenkataraman, S.. 2026-06-24. A Universal Free-Degree Orientation Extrusion Head Enables Conformal and Non-Planar Bio-Additive Manufacturing toward Adaptive and Future-Ready Bioprinting. https://doi.org/10.64898/2026.06.23.734010

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