Bioinspired Designs for Additive Manufacturing in Advanced Engineering Applications

A special issue of Biomimetics (ISSN 2313-7673). This special issue belongs to the section "Biomimetics of Materials and Structures".

Deadline for manuscript submissions: closed (20 June 2025) | Viewed by 5168

Special Issue Editor


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Guest Editor
1. Department of Mechanical and Materials Engineering, University of Turku, Turku, Finland
2. Turku Clinical Biomaterials Centre (TCBC), Department of Biomaterials Science, Faculty of Medicine, Institute of Dentistry, University of Turku, Turku, Finland
3. Department of Mechanical and Industrial Engineering, Tallinn University of Technology, Tallinn, Estonia
Interests: additive manufacturing; biomimetic design; bioinspired materials; tissue engineering

Special Issue Information

Dear Colleagues,

The recent advances and the implementation of research in the areas of bio-inspired design and additive manufacturing have led to applications of various fields, such as aerospace, maritime, nuclear, defense, acoustic, thermal, soft machines, robots, bio-interfaces, and health care applications. Functional materials and systems that imitate the properties or mechanisms of biological tissues, agents, and behaviors are abundant in biology. Additive manufacturing has enabled the fabrication of materials and structures that are prevalent in biology, with lessons learned from nature leading to more lightweight structures. The development of low-cost manufacturing technologies allows various engineering applications of effective bio-inspired structures and the understanding and collection of naturally occurring structures that could further facilitate simulation-driven design and selection of the design outcome most similar to the biological structure will likely be the best solution for the manufacturing technologies. This can further enable the possibility of data-driven methodologies and machine learning (ML) in engineering structural design. Furthermore, the novel paradigm of the ML-based approach can largely accelerate the new material design, boasting orders of magnitude increases in computational efficacy over conventional methods for advanced engineering applications.  

This Special Issue, titled “Bioinspired Designs for Additive Manufacturing in Advanced Engineering Applications”, aims to exhibit new research achievements, findings, perspectives, and ideas for the future development of bioinspired new functional materials. Some of its focal points include but are not limited to the following:

  1. Bioinspiration of natural synthetic mechanisms and biomimetic principles for additive manufacturing;
  2. Biostructures in the form of lamellar, columnar, coaxial layered, and array structured for bio functions like acoustic, optical, thermal, electrical, mechanical, and magnetic properties;
  3. Machine learning-assisted bioinspired designs for superior mechanical performances.

It is our pleasure to invite you to submit a manuscript for this Special Issue. Full papers, short communications, and reviews are welcome.

Dr. Nikhil Kamboj
Guest Editor

Manuscript Submission Information

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Keywords

  • strategies and concepts of bioinspired designs
  • additive manufacturing
  • applications and performances of bioinspired materials (e.g., aerospace, maritime, nuclear, defense, acoustic, thermal, soft machines, robots, bio-interfaces, and health care)
  • processing of bioinspired materials
  • functional materials
  • simulations-driven design
  • simulations of bioinspired materials at all length scales
  • machine learning
  • mechanical properties

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Published Papers (4 papers)

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Research

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20 pages, 23283 KiB  
Article
Titanium–Aluminum–Vanadium Surfaces Generated Using Sequential Nanosecond and Femtosecond Laser Etching Provide Osteogenic Nanotopography on Additively Manufactured Implants
by Jonathan T. Dillon, David J. Cohen, Scott McLean, Haibo Fan, Barbara D. Boyan and Zvi Schwartz
Biomimetics 2025, 10(8), 507; https://doi.org/10.3390/biomimetics10080507 - 4 Aug 2025
Viewed by 418
Abstract
Titanium–aluminum–vanadium (Ti6Al4V) is a material chosen for spine, orthopedic, and dental implants due to its combination of desirable mechanical and biological properties. Lasers have been used to modify metal surfaces, enabling the generation of a surface on Ti6Al4V with distinct micro- and nano-scale [...] Read more.
Titanium–aluminum–vanadium (Ti6Al4V) is a material chosen for spine, orthopedic, and dental implants due to its combination of desirable mechanical and biological properties. Lasers have been used to modify metal surfaces, enabling the generation of a surface on Ti6Al4V with distinct micro- and nano-scale structures. Studies indicate that topography with micro/nano features of osteoclast resorption pits causes bone marrow stromal cells (MSCs) and osteoprogenitor cells to favor differentiation into an osteoblastic phenotype. This study examined whether the biological response of human MSCs to Ti6Al4V surfaces is sensitive to laser treatment-controlled micro/nano-topography. First, 15 mm diameter Ti6Al4V discs (Spine Wave Inc., Shelton, CT, USA) were either machined (M) or additively manufactured (AM). Surface treatments included no laser treatment (NT), nanosecond laser (Ns), femtosecond laser (Fs), or nanosecond followed by femtosecond laser (Ns+Fs). Surface wettability, roughness, and surface chemistry were determined using sessile drop contact angle, laser confocal microscopy, X-ray photoelectron spectroscopy (XPS), and scanning electron microscopy (SEM). Human MSCs were cultured in growth media on tissue culture polystyrene (TCPS) or test surfaces. On day 7, the levels of osteocalcin (OCN), osteopontin (OPN), osteoprotegerin (OPG), and vascular endothelial growth factor 165 (VEGF) in the conditioned media were measured. M NT, Fs, and Ns+Fs surfaces were hydrophilic; Ns was hydrophobic. AM NT and Fs surfaces were hydrophilic; AM Ns and Ns+Fs were hydrophobic. Roughness (Sa and Sz) increased after Ns and Ns+Fs treatment for both M and AM disks. All surfaces primarily consisted of oxygen, titanium, and carbon; Fs had increased levels of aluminum for both M and AM. SEM images showed that M NT discs had a smooth surface, whereas AM surfaces appeared rough at a higher magnification. Fs surfaces had a similar morphology to their respective NT disc at low magnification, but higher magnification revealed nano-scale bumps not seen on NT surfaces. AM Fs surfaces also had regular interval ridges that were not seen on non-femto laser-ablated surfaces. Surface roughness was increased on M and AM Ns and Ns+Fs disks compared to NT and Fs disks. OCN was enhanced, and DNA was reduced on Ns and Ns+Fs, with no difference between them. OPN, OPG, and VEGF levels for laser-treated M surfaces were unchanged compared to NT, apart from an increase in OPG on Fs. MSCs grown on AM Ns and Ns+Fs surfaces had increased levels of OCN per DNA. These results indicate that MSCs cultured on AM Ns and AM Ns+Fs surfaces, which exhibited unique roughness at the microscale and nanoscale, had enhanced differentiation to an osteoblastic phenotype. The laser treatments of the surface mediated this enhancement of MSC differentiation and warrant further clinical investigation. Full article
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12 pages, 2399 KiB  
Article
Towards Self-Assembling 3D-Printed Shapes Through Βiomimetic Μechanical Interlocking
by Tino Marte, Savvas Koltsakidis, Thomas Profitiliotis, Emmanouil Tzimtzimis and Dimitrios Tzetzis
Biomimetics 2025, 10(6), 400; https://doi.org/10.3390/biomimetics10060400 - 13 Jun 2025
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Abstract
While early studies on macroscopic self-assembly peaked in the late 20th century, recent research continues to explore and expand the field’s potential through innovative materials and external control strategies. To harness this potential, a unit cell was designed and 3D-printed that could form [...] Read more.
While early studies on macroscopic self-assembly peaked in the late 20th century, recent research continues to explore and expand the field’s potential through innovative materials and external control strategies. To harness this potential, a unit cell was designed and 3D-printed that could form a face-centered cubic lattice and stabilize it through a biomimetic mechanism for mechanical interlocking. The wing coupling structures of the brown marmorated stink bug were examined under a scanning electron microscope to be used as a source of bio-inspiration for the interlocking mechanism. A total of 20 unit cells were studied in five different self-assembly processes and in different compression scenarios. A maximum average of 34% of unit cells remained stable, and 20% were mechanically interlocked after self-assembly tests. The compression tests performed on a single unit cell revealed that the cell can withstand forces up to 1000 N without any plastic deformation. Pyramid configurations from 5-unit cells were manually assembled and assessed in compression tests. They showed an average compression force of 294 N. As the first study focused on self-assembly through mechanical interlocking, further studies that change the unit cell production and self-assembly processes are expected to improve upon these results. Full article
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22 pages, 6009 KiB  
Article
Teaching Bioinspired Design for Assistive Technologies Using Additive Manufacturing: A Collaborative Experience
by Maria Elizete Kunkel, Alexander Sauer, Carlos Isaacs, Thabata Alcântara Ferreira Ganga, Leonardo Henrique Fazan and Eduardo Keller Rorato
Biomimetics 2025, 10(6), 391; https://doi.org/10.3390/biomimetics10060391 - 11 Jun 2025
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Abstract
Integrating bioinspired design and additive manufacturing into engineering education fosters innovation to meet the growing demand for accessible, personalized assistive technologies. This paper presents the outcomes of an international course, “3D Prosthetics and Orthotics”, offered to undergraduate students in the Biomimetic program at [...] Read more.
Integrating bioinspired design and additive manufacturing into engineering education fosters innovation to meet the growing demand for accessible, personalized assistive technologies. This paper presents the outcomes of an international course, “3D Prosthetics and Orthotics”, offered to undergraduate students in the Biomimetic program at Westfälische Hochschule (Germany), in collaboration with the 3D Orthotics and Prosthetics Laboratory at the Federal University of São Paulo—UNIFESP (Brazil). The course combined theoretical and hands-on modules covering digital modeling (CAD), simulation (CAE), and fabrication (CAM), enabling students to develop bioinspired assistive devices through a Project-based learning approach. Working in interdisciplinary teams, students addressed real-world rehabilitation challenges by translating biological mechanisms into engineered solutions using additive manufacturing. Resulting prototypes included a hand prosthesis based on the Fin Ray effect, a modular finger prosthesis inspired by tendon–muscle antagonism, and a cervical orthosis designed based on stingray morphology. Each device was digitally modeled, mechanically analyzed, and physically fabricated using open-source and low-cost methods. This initiative illustrates how biomimetic mechanisms and design can be integrated into education to generate functional outcomes and socially impactful health technologies. Grounded in the Mao3D open-source methodology, this experience demonstrates the value of combining nature-inspired principles, digital fabrication, Design Thinking, and international collaboration to advance inclusive, low-cost innovations in assistive technology. Full article
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Review

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37 pages, 6555 KiB  
Review
Biomimetic Lattice Structures Design and Manufacturing for High Stress, Deformation, and Energy Absorption Performance
by Víctor Tuninetti, Sunny Narayan, Ignacio Ríos, Brahim Menacer, Rodrigo Valle, Moaz Al-lehaibi, Muhammad Usman Kaisan, Joseph Samuel, Angelo Oñate, Gonzalo Pincheira, Anne Mertens, Laurent Duchêne and César Garrido
Biomimetics 2025, 10(7), 458; https://doi.org/10.3390/biomimetics10070458 - 12 Jul 2025
Viewed by 1513
Abstract
Lattice structures emerged as a revolutionary class of materials with significant applications in aerospace, biomedical engineering, and mechanical design due to their exceptional strength-to-weight ratio, energy absorption properties, and structural efficiency. This review systematically examines recent advancements in lattice structures, with a focus [...] Read more.
Lattice structures emerged as a revolutionary class of materials with significant applications in aerospace, biomedical engineering, and mechanical design due to their exceptional strength-to-weight ratio, energy absorption properties, and structural efficiency. This review systematically examines recent advancements in lattice structures, with a focus on their classification, mechanical behavior, and optimization methodologies. Stress distribution, deformation capacity, energy absorption, and computational modeling challenges are critically analyzed, highlighting the impact of manufacturing defects on structural integrity. The review explores the latest progress in hybrid additive manufacturing, hierarchical lattice structures, modeling and simulation, and smart adaptive materials, emphasizing their potential for self-healing and real-time monitoring applications. Furthermore, key research gaps are identified, including the need for improved predictive computational models using artificial intelligence, scalable manufacturing techniques, and multi-functional lattice systems integrating thermal, acoustic, and impact resistance properties. Future directions emphasize cost-effective material development, sustainability considerations, and enhanced experimental validation across multiple length scales. This work provides a comprehensive foundation for future research aimed at optimizing biomimetic lattice structures for enhanced mechanical performance, scalability, and industrial applicability. Full article
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