A research team led by Alshakim Nelson at the University of Washington is exploring new materials for 3D printing with a focus on sustainability and biological functionality. Rather than optimizing printer hardware, the team develops its own printable bioplastics that are fully biodegradable while offering mechanical properties comparable to traditional 3D printing polymers.
“We needed a material that was 3D printable and biodegradable but also had good mechanical properties,” Nelson says. “It had to be competitive with the commercial plastics [for 3D printing] that are out there today.”
“It feels like cooking, except the ingredients are limitless, and the kinds of things you can make are also limitless,” is how Angus Berg, an undergraduate student working in Nelson’s lab (see video below), describes the research.
Stronger When Stressed“Proteins are biodegradable and can be bio-sourced, so we wanted to see if we could fit them into the 3D-printing lifecycle,” says Nelson. “Then we wanted to see if we could shape them and create more complex designs [through 3D printing] that would still biodegrade at the end of the lifecycle.”
The core of the project revolves around proteins as a feedstock. These are biologically derived and, due to their molecular structure, suitable for forming complex geometries. Combined with specialized printing strategies, the materials not only offer stability but can also deform under stress and return to a stronger configuration. A lattice design co-developed with Professor Lucas Meza allows these biopolymers to reinforce themselves under mechanical load without cracking. This behavior is supported by energy distribution within the microstructure and offers potential for applications in medical devices and lightweight construction.
“I have a really great team of students and postdocs who make excellent observations,” Nelson says. “They’re just being good scientists, noticing when something interesting happens [in an experiment] and should be looked into more.”
The team is also working on functional materials that incorporate therapeutic agents. One example is a 3D-printed stent that continuously releases anti-inflammatory compounds, generated by microorganisms embedded within the material. These biological systems remain viable for extended periods and can be stored in dried form for up to six months, then reactivated when needed.
“One of the cool things we’ve discovered is that these materials stay viable for extended periods of time,” says Nelson. “They can continuously produce the desired compounds for a year or longer. They’re also shelf-stable in a dried state for six months. That means we can store them until we need them and then take them off the shelf and put them into media and start producing very quickly. The big dream is to think about using these for manufacturing on a more local scale and maybe in smaller volumes as needed.”
This concept also holds potential for space missions. In long-duration missions, such as a trip to Mars, these systems could support autonomous medical supply chains.
“If you think about a mission to Mars that takes almost two years, you have to take everything with you,” Nelson says. “Could we use these types of printable structures for the on-demand production of different therapeutic compounds? Could this kind of bioproduction be done in space? I think it is possible.”
Looking ahead, Nelson aims to expand the use of plant-based proteins, such as those derived from genetically modified rice. These could improve the environmental footprint of 3D printing while maintaining functional integrity.
“We recently found that we can print with a protein from genetically engineered rice,” Nelson says. “It has good properties and can also provide new functions, so I’m excited about that. It’s just another opportunity for us to use our imaginations about what’s possible now — and what’s next.”
The overarching goal is to integrate biodegradable, multifunctional materials into additive manufacturing—not just as replacements, but as a distinct class of materials in their own right.
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