Volumetric Control vs. Pneumatic Pressure: A Comparative Analysis of Extrusion in 3D Bioprinting

Extrusion-based bioprinting faces significant challenges in achieving the shape fidelity and internal porosity necessary for cell viability, often hindered by subjective assessment methods. This study investigated the relationship between rheological properties and print quality using a natural polymer biomaterial ink composed of 12% gelatin, 5% alginate, and 1% carboxymethylcellulose. We conducted a comparative analysis between traditional pneumatic systems and screw-driven volumetric extrusion, utilizing a suite of quantitative metrics: Spreading Ratio (SR), Printability Index (Pr), Uniformity Ratio (UF), Collapse Angle (θ), and evaluated porosity. Our results demonstrate that the screw-driven system’s positive displacement mechanism provides superior control over filament morphology by enabling precise volumetric modulation. While the pneumatic system exhibited a high SR of 1.82 and the lowest porosity at 59.92%, the screw-driven system allowed for “under-extrusion” to compensate for viscoelastic die swell. Reducing the flow rate to 50% in the screw system lowered the SR to 1.09, nearly matching the nozzle diameter, and increased porosity to 76.46%. Furthermore, the screw-driven system achieved an ideal Pr of 1.0, whereas the pneumatic system produced distorted, rounded pores with a Pr of 1.57. The findings indicate that screw-driven extruders can decouple line complex rheology from the printing process, allowing for finer spatial resolution and better pore interconnectivity.