Design and Validation of a Piston-Driven Syringe-Extrusion Bioprinter Using an FDM Frame

Abstract

Direct ink writing (DIW) deposits viscous, shear-responsive inks at low temperature, enabling hydrogels and cell-laden bioinks for biomedical fabrication. Access to DIW remains limited by the cost of dedicated systems and the complexity of custom motion control. Repurposing fused deposition modeling (FDM) printers lowers these barriers by using accurate motion stages, open firmware, and familiar workflows while preserving build volume. In this study, three DIW actuator designs were implemented on an FDM frame. The first used a gear-and-rail transmission that converted stepper rotation to plunger travel. The second used a direct trapezoidal-screw pusher that increased force but reduced build-space clearance. The third relocated actuation to a remote piston-driven module that decoupled force generation from the printhead. The final architecture integrates the remote piston with partitioned control, where the printer executes motion and a programmable logic controller (PLC) manages extrusion. This arrangement reduces carried mass, preserves build space, and enables precise volumetric dosing with fast response. On a standard desktop frame, the system achieved controllable deposition of an agar/alginate ink using off-the-shelf electronics and modest modifications. This approach promotes sustainable and accessible innovation by repurposing existing FDM printers with open-source hardware and modular components. The resulting platform supports biomimetic biofabrication by combining mechanical efficiency, environmental responsibility, and cost-effective design.