Methodological framework for fused filament fabrication of 3D-printed beads for cell immobilization in bioprocesses

This study presents an innovative methodology for fabricating polymeric beads via 3D printing to enhance cell immobilization strategies in bioprocess engineering. Using fused filament fabrication (FFF), beads composed of acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) were fabricated with precisely tailored geometries, enabling the systematic evaluation of how material type and internal design influence both manufacturing feasibility and structural stability. The methodology demonstrates high reproducibility, dimensional accuracy and flexibility, allowing researchers to fabricate immobilization beads adapted to specific bioprocess conditions. In contrast to conventional immobilization matrices, this FFF-based approach offers a scalable, cost-effective and customizable alternative, capable of producing complex porous architectures that promote microbial adhesion and mass transfer. The method stands out for extending additive manufacturing applications beyond enzyme immobilization toward whole-cell biocatalyst systems, providing a valuable framework for future biotechnological process development. • A reproducible FFF-based workflow for 3D-printed cell immobilization beads. • ABS and PLA beads fabricated with tunable geometry and internal porosity. • Method extends 3D printing applications from enzymes to whole-cell biocatalysts. • Cost-effective and scalable alternative to conventional immobilization matrices.