Advanced International Journal for Research

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Volume 7 Issue 5
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An Open-Source Continuous Fiber Extruder for Long-Fiber Reinforced Hydrogel Bioprinting

Author(s) Pankaj Wankhede, Sanket Momte, Hashim Sheikh, Meet Deshmukh, Vishesh Asoor
Country India
Abstract Hydrogels are widely explored in biomedical engineering, soft robotics, and
biofabrication due to their high water content, flexibility, and biocompatibility.
However, their limited mechanical strength often restricts their use in
applications requiring structural stability or load resistance. In this work, a
compact and cost-effective Continuous Fiber Extruder (CFE) is developed and
integrated with a standard desktop 3D printer to enable the embedding of long,
continuous fibers within hydrogel constructs during printing. The system is
designed using open-source hardware and employs compliant silicone rollers
driven by a microstepped stepper motor to ensure smooth and damage-free
feeding of delicate fibers. The CFE operates alongside a syringe-based hydrogel
extruder and is compatible with the Freeform Reversible Embedding of
Suspended Hydrogels (FRESH) printing approach. Experimental calibration
confirms accurate control of fiber feed length, achieving positional accuracy
greater than 98% across multiple embedding patterns. Mechanical testing of
reinforced hydrogel specimens demonstrates significant enhancement in tensile
performance, with strength and stiffness improvements observed depending on
the fiber material and layout. The proposed extruder provides an accessible and
reproducible platform for fabricating mechanically reinforced hydrogel
composites using low-cost desktop equipment. This approach lowers the barrier
to long-fiber embedded hydrogel printing and supports further research in
bioinspired structures, soft functional materials, and biomedical applications.
Keywords Hydrogels; Continuous Fiber Extruder (CFE); FRESH; 3D bioprinting; Reinforcement; Replistruder
Published In Volume 7, Issue 5, September-October 2026
Published On 2026-09-17
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E-ISSN 3048-7641
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