A Novel Non-Planar Bioprinting Methodology for Enhanced Surface Fidelity of the Cornea

Traditional 3D bioprinting of corneal constructs relies on planar slicing, which often results in a significant stairstep effect and the loss of anatomical curvature. Curvilinear layering has emerged as a promising alternative to address these limitations. The presented methodology, based on non-planar layer integration, ensures a smoother surface finish. The model’s surface is identified via vertex normals and reconstructed using the Poisson method. Finally, surface parametrization is applied to generate spatially curved trajectories. To validate the algorithm, corneal constructs were printed using a planar and the proposed non-planar approach. Quantitative evaluation of micro-Computed Tomography data revealed that the non-planar approach achieved significantly higher morphological fidelity, successfully replicating the intended parabolic profile of the human cornea. Furthermore, the non-planar constructs demonstrated adequate functional performance, characterized by high optical transparency. Thereby, the feasibility of printing non-planar layers using the proposed novel approach is successfully demonstrated. Furthermore, the comparative analysis confirms the method’s potential for corneal biofabrication when compared to traditional planar methods.