Biopolymer—Nanoparticle Interactions in 3D-Printing for Biomedical Applications: Advantages, Limitations and Future Perspectives

This review comprehensively examines the incorporation of nanoparticles (NPs) into biopolymers for 3D printing in biomedical applications, integrating material design, processing strategies, and translational considerations within a unified framework. Different types of NPs are analyzed regarding their effects on mechanical reinforcement, rheological modulation, and structural organization of biopolymeric matrices. The discussion covers principal additive manufacturing technologies, including extrusion-based systems such as fused deposition modeling (FDM) and direct ink writing (DIW), vat photopolymerization, powder-bed fusion (SLS), and emerging in situ nanoparticle formation approaches, emphasizing how nanoparticle loading and surface functionalization govern yield stress, shear-thinning behavior, viscoelastic recovery, and dimensional fidelity while mitigating agglomeration and optimizing interfacial interactions. Comparative evaluation of compressive modulus, strength, toughness, crystallinity, and porosity establishes structure–property–processing relationships directly linked to printability and functional performance. Biomedical applications are addressed in tissue engineering, biosensing, controlled and targeted drug delivery, and bioimaging, highlighting the balance between bioactivity and manufacturability. Finally, critical challenges—including compatibility, reproducibility, biological safety, long-term stability, regulatory adaptation, and environmental impact—are discussed, alongside future perspectives focused on green nanomaterials, AI-driven predictive formulation design, and digital twins for real-time monitoring and quality control in nano-enabled additive manufacturing.