Segmentation approach for enhanced DLP bioprinting

High-resolution Digital Light Processing (DLP) bioprinting requires precise control over photocrosslinking, particularly for complex models with fine gaps. This study presents a novel segmentation approach that utilizes the DLP system's diffusion characteristics, avoiding alterations to core components. The method segments the photomask into discrete regions and employs an on-off activation strategy to regulate the distribution and concentration of free radicals, enabling printing with 100 µm gaps between bronchial branches at a 14.43x compression ratio. Demonstrated by printing a bronchial model with intricate structures, the approach achieved up to 90% cell viability for GelMA and 85% for GelMA-PEGDA over seven days.