Bridging rheology and bioprinting: A predictive framework for safe and precise extrusion bioprinting parameters

Extrusion‐based bioprinting has become increasingly common due to its high cell viability, compatibility with diverse crosslinking mechanisms, and ability to print at high cell densities with minimal cellular damage. However, most fabrication workflows still rely on trial-and-error optimization, leading to time-consuming, increased material costs, and reduced reproducibility. Here, we introduce a simple and yet robust mathematical model that predicts the extrusion pressure required for printing directly from rheological data, enabling the construction of a pressure-based printability window that reduces optimization time and resource use. The predicted pressures were further used to estimate wall shear stress, providing a pre-print assessment of safe-to-print conditions. The model achieved a 5–15% relative error compared with experimentally adjusted printing pressures across multiple nozzle types. All bioprinted constructs maintained >80% cell viability, and the predicted shear stress remained below reported thresholds for fibroblast safety, confirming the model’s reliability for guiding extrusion bioprinting.