Applications of 3D printing in biofilm engineering and high-throughput diagnostics development

Abstract

Three-dimensional (3D) printing is a versatile and transformative manufacturing technology, enabling the creation of complex structures across a wide range of materials and methods. In this dissertation I describe two applications of 3D printing: the bioprinting of microbial biofilm models and the rapid prototyping of pathogen diagnostic systems. Biofilms play important roles in ecosystems, while also posing significant challenges to human health and infrastructure. Their complexity and heterogeneity influence key functions such as antibiotic resistance and bioprocessing. However, existing in vitro methods of studying biofilms lack control over structure and composition, limiting comprehensive studies. To address this, I develop a light-based 3D printing method to fabricate synthetic biofilm models with bacteria embedded in hydrogels. This method allows for controlled modulation of biofilm heterogeneity, enabling systematic exploration of structure-function relationships and ultimately providing a framework for engineering synthetic biofilms with controlled characteristics. I also apply the rapid prototyping abilities of 3D printing to develop novel diagnostic tools. Rapid and accessible diagnostic testing is crucial for pandemic preparedness, yet existing methods are often slow, costly, or reliant on centralized laboratories. To address these limitations, I leverage 3D printing to develop a high-throughput diagnostic workflow with automated fluorescence detection, achieving processing speeds of over 2,100 samples per hour. This diagnostic platform demonstrates the potential of 3D printing to facilitate the rapid development and deployment of diagnostic tools, which is essential for timely and efficient disease response. Together, these projects illustrate how advanced manufacturing technologies like 3D printing can drive innovation in biotechnology and healthcare, ultimately contributing to improved disease management and scientific advancement.