Development of Nanocoated Filaments for 3D Fused Deposition Modeling of Antibacterial and Antioxidant Materials

Three-dimensional (3D) printing is one of the most futuristic manufacturing technologies, allowing on-demand manufacturing of products with highly complex geometries and tunable material properties. Among the different 3D-printing technologies, fused deposition modeling (FDM) is the most popular one due to its affordability, adaptability, and pertinency in many areas, including the biomedical field. Yet, only limited amounts of materials are commercially available for FDM, which hampers their application potential. Polybutylene succinate (PBS) is one of the biocompatible and biodegradable thermoplastics that could be subjected to FDM printing for healthcare applications. However, microbial contamination and the formation of biofilms is a critical issue during direct usage of thermoplastics, including PBS. Herein, we developed a composite filament containing polybutylene succinate (PBS) and lignin for FDM printing. Compared to pure PBS, the PBS/lignin composite with 2.5 similar to 3.5% lignin showed better printability and antioxidant and antimicrobial properties. We further coated silver/zinc oxide on the printed graft to enhance their antimicrobial performance and obtain the strain-specific antimicrobial activity. We expect that the developed approach can be used in biomedical applications such as patient-specific orthoses.