Enhancing Microalgal Growth through Integrated Computational Modeling and 3D Bioprinting

Efficient cultivation of microalgae for biofuel and bioproduct applications is often limited by suboptimal light distribution, poor mass transfer, and large land footprint requirements in conventional flat biofilm and open-pond systems. In this study, we combine computational modeling, 3D bioprinting, and experimental measurements to design and evaluate the role of different geometries for photosynthetic production in bioprinted microalgal constructs. Specifically, we investigate a perforated slab with channels (PS) and Vgroove structures, which show enhanced algal growth performance compared to flat slabs of the same volume and footprint. By integrating experimentally measured photosynthetic parameters into radiative transfer and oxygen diffusion-reaction simulations, we uncover the role of structure induced improvements in light penetration, surface area-to-volume ratio, and mass transfer dynamics driving increased algal growth and photosynthesis. Algal growth rates in printed PS and Vgroove geometries were 2.4 and 1.3 times higher, respectively, than in corresponding slab. These findings demonstrate the potential of engineered 3D bioprinted architectures to optimize photosynthetic efficiency and growth rates while minimizing spatial footprint, paving the way for compact, high-throughput bioreactors for sustainable algal cultivation. Beyond biofuel production, these microalgal systems enable sustainable CO2 capture and utilization.