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Purpose <p>Additive manufacturing (AM) enables the fabrication of anatomically precise, patient-specific scaffolds for intervertebral disc (IVD) repair. This study aims to establish an integrated workflow combining computer-aided design (CAD), computational fluid dynamics (CFD), and mechanical-rheological characterization for the development of patient-specific annulus fibrosus (AF) scaffolds and to describe the gelatin–alginate bioink formulation for the fabrication of personalized structures for 3D bioprinting applications with this integrated approach.</p> Methods <p>The L5–S1 AF geometry was reconstructed from cadaveric imaging data and converted into STL format for extrusion-based 3D bioprinting. Scaffold permeability and wall shear stress (WSS) were optimized via Computational Fluid Dynamics (CFD) guided pore design. Gelatin–alginate hydrogels (7–9% alginate, 3–5% gelatin) were characterized by unconfined compression (0–10% strain) and rheology. Bioprinted scaffolds were evaluated for shape fidelity, porosity, and preliminary L929 fibroblast biocompatibility.</p> Results <p>Bioinks showed tunable Young’s modulus values of 2.23 ± 0.4 to 3.01 ± 0.6&#xa0;MPa, within the physiological compressive range of native AF tissue (0.4–3&#xa0;MPa). The 8% alginate − 4% gelatin blend (2.6 ± 0.4&#xa0;MPa; tan δ = 0.46) balanced stiffness, deformability, and printability. CFD-guided pore designs enhanced predicted nutrient diffusion while preserving structure. Bioprinted scaffolds replicated patient-specific geometry and supported L929 cell viability and adhesion.</p> Conclusion <p>This integrated CAD, CFD, and mechanorheological approach provides an effective framework for developing personalized AF scaffolds. In this workflow, an 8% alginate-4% gelatin formulation is recommended for AF tissue and offers a potential alternative to standard surgical approaches, paving the way for future patient-specific regenerative therapies.</p>

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High-Precision Design and Additive Manufacturing of Patient-Specific L5-S1 Annulus Fibrosus Scaffolds: A CFD-Optimized and Biomechanical Approach

  • 期刊论文

  • 发表日期：

    2026年5月8日

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  • Banuay Coşkun,
  • Özlem Biçen Ünlüer

摘要

Purpose

Additive manufacturing (AM) enables the fabrication of anatomically precise, patient-specific scaffolds for intervertebral disc (IVD) repair. This study aims to establish an integrated workflow combining computer-aided design (CAD), computational fluid dynamics (CFD), and mechanical-rheological characterization for the development of patient-specific annulus fibrosus (AF) scaffolds and to describe the gelatin–alginate bioink formulation for the fabrication of personalized structures for 3D bioprinting applications with this integrated approach.

Methods

The L5–S1 AF geometry was reconstructed from cadaveric imaging data and converted into STL format for extrusion-based 3D bioprinting. Scaffold permeability and wall shear stress (WSS) were optimized via Computational Fluid Dynamics (CFD) guided pore design. Gelatin–alginate hydrogels (7–9% alginate, 3–5% gelatin) were characterized by unconfined compression (0–10% strain) and rheology. Bioprinted scaffolds were evaluated for shape fidelity, porosity, and preliminary L929 fibroblast biocompatibility.

Results

Bioinks showed tunable Young’s modulus values of 2.23 ± 0.4 to 3.01 ± 0.6 MPa, within the physiological compressive range of native AF tissue (0.4–3 MPa). The 8% alginate − 4% gelatin blend (2.6 ± 0.4 MPa; tan δ = 0.46) balanced stiffness, deformability, and printability. CFD-guided pore designs enhanced predicted nutrient diffusion while preserving structure. Bioprinted scaffolds replicated patient-specific geometry and supported L929 cell viability and adhesion.

Conclusion

This integrated CAD, CFD, and mechanorheological approach provides an effective framework for developing personalized AF scaffolds. In this workflow, an 8% alginate-4% gelatin formulation is recommended for AF tissue and offers a potential alternative to standard surgical approaches, paving the way for future patient-specific regenerative therapies.