Three-dimensional printing and nanotechnology for enhanced implantable materials

Orthopedic and oro-maxillofacial implants have revolutionized treatment of bone diseases and fractures. Currently available metallic implants have been in clinical use for more than 40 years and have proved medically efficacious. However, several drawbacks remain, such as excessive stiffness, accumulation of metal ions in surrounding tissue, growth restriction, required removal/revision surgery, inability to carry drugs, and susceptibility to infection. The need for additional revision surgery increases financial costs and prolongs recovery time for patients. These metallic implants are bulk manufactured and often do not meet patient\u27s requirements. A surgeon must machine (cut, weld, trim or drill holes) them in order to best suit the patient specifications. Over the past few decades, attempts have been made to replace these metallic implants with suitable biodegradable materials to prevent secondary/revision surgery. Recent advances in biomaterials have shown multiple uses for lactic acid polymers in bone implant technology. However, a targeted/localized drug delivery system needs to be incorporated in these polymers, and they need to be customized to treat orthopedic implant-related infections and other bone diseases such as osteomyelitis, osteosarcoma and osteoporosis. Rapid Prototyping (RP) using additive manufacturing (AM) or 3D printing could allow customization of constructs for personalized medicine. The goal of this study was to engineer customizable and biodegradable implant materials that can elute bioactive compounds for personalized medicine and targeted drug delivery. Post-operative infections are the most common complications following dental, orthopedic and bone implant surgeries. Preventing post-surgical infections is therefore a critical need that current polymethylmethacrylate (PMMA) bone cements fail to address. Calcium Phosphate Cements (CPCs) are unique in their ability to crystallize calcium and phosphate salts into hydroxyapatite (HA) and hence is naturally osteoconductive. Due to its low mechanical strength, its use in implant fixation and bone repair is limited to nonload-bearing applications. Novel CPCs were formulated and were doped with drug loaded Halloysite Nanotubes (HNTs) to enhance their mechanical and anti-infective properties. In this study we also explored the use of customized biopolymer filaments and 3D printing technology to treat bone diseases such as osteomyelitis, osteosarcoma, and osteoporosis. Biopolymer filaments were successfully loaded with antibiotics, chemotherapeutics and hormones (female sex hormones). Using a Fused Deposition Modeling (FDM)-based 3D printer, these customized filaments were fabricating into 3D scaffolds. Constructs with variable mechanical strengths and porosities were successfully designed and 3D printed. Scanning electron microscopy was used to study the surface architecture of the scaffolds. Compression and flexural testing was conducted for testing the mechanical strength of the constructs. Bacterial and suitable cell culture studies were applied to test bioactivity of the constructs. From above experiments, this study showed that 3D printing technology can be used to fabricate bioactive biopolymers for personalized medicine and localized drug delivery

Nanogels for pharmaceutical and biomedical applications and their fabrication using 3D printing technologies

Nanogels are hydrogels formed by connecting nanoscopic micelles dispersed in an aqueous medium, which give an opportunity for incorporating hydrophilic payloads to the exterior of the micellar networks and hydrophobic payloads in the core of the micelles. Biomedical and pharmaceutical applications of nanogels have been explored for tissue regeneration, wound healing, surgical device, implantation, and peroral, rectal, vaginal, ocular, and transdermal drug delivery. Although it is still in the early stages of development, due to the increasing demands of precise nanogel production to be utilized for personalized medicine, biomedical applications, and specialized drug delivery, 3D printing has been explored in the past few years and is believed to be one of the most precise, efficient, inexpensive, customizable, and convenient manufacturing techniques for nanogel production

Calcium Phosphate/Clay Nanotube Bone Cement with Enhanced Mechanical Properties and Sustained Drug Release

Calcium phosphate cement (CPC) has limited use in bone repair due to their poor mechanical properties. Halloysite nanotubes (HNTs) are clay tubes with an aluminosilicate composition. The physicochemical properties, cytocompatibility, and cellular response to the CPC/HNT composites were assayed. Compression strength, FTIR analysis, protein synthesis, and mineralization were assessed. The cumulative data show that composites of tricalcium phosphate (TCP), anhydrous calcium diphosphate (DCPA) as the solid phase agent, and 10% chitosan lactate solution as the setting liquid produced cement with sustained release properties without loss of material strength. The composite also showed enhanced material properties (adhesiveness, surface roughness, and increased strength). Cellular assays confirm its osteoconductive and osteoinductive nature. CPCs, loaded with gentamicin- and neomycin-doped HNTs, showed sustained antibacterial release and marked zone of growth inhibition. CPCs fabricated with drug-doped HNTs offer a means for inducing bone growth at the site of implantation while controlling infection. This treatment modality should hasten patient healing time and enhance restoration of function. The increase in materials properties suggests that this CPC may be clinically applied to repair injuries in load-bearing bones

Novel Biomaterials Used in Medical 3D Printing Techniques

The success of an implant depends on the type of biomaterial used for its fabrication. An ideal implant material should be biocompatible, inert, mechanically durable, and easily moldable. The ability to build patient specific implants incorporated with bioactive drugs, cells, and proteins has made 3D printing technology revolutionary in medical and pharmaceutical fields. A vast variety of biomaterials are currently being used in medical 3D printing, including metals, ceramics, polymers, and composites. With continuous research and progress in biomaterials used in 3D printing, there has been a rapid growth in applications of 3D printing in manufacturing customized implants, prostheses, drug delivery devices, and 3D scaffolds for tissue engineering and regenerative medicine. The current review focuses on the novel biomaterials used in variety of 3D printing technologies for clinical applications. Most common types of medical 3D printing technologies, including fused deposition modeling, extrusion based bioprinting, inkjet, and polyjet printing techniques, their clinical applications, different types of biomaterials currently used by researchers, and key limitations are discussed in detail

Recent Advances in Biomaterials for 3D Printing and Tissue Engineering

Three-dimensional printing has significant potential as a fabrication method in creating scaffolds for tissue engineering. The applications of 3D printing in the field of regenerative medicine and tissue engineering are limited by the variety of biomaterials that can be used in this technology. Many researchers have developed novel biomaterials and compositions to enable their use in 3D printing methods. The advantages of fabricating scaffolds using 3D printing are numerous, including the ability to create complex geometries, porosities, co-culture of multiple cells, and incorporate growth factors. In this review, recently-developed biomaterials for different tissues are discussed. Biomaterials used in 3D printing are categorized into ceramics, polymers, and composites. Due to the nature of 3D printing methods, most of the ceramics are combined with polymers to enhance their printability. Polymer-based biomaterials are 3D printed mostly using extrusion-based printing and have a broader range of applications in regenerative medicine. The goal of tissue engineering is to fabricate functional and viable organs and, to achieve this, multiple biomaterials and fabrication methods need to be researched

Novel Biomaterials Used in Medical 3D Printing Techniques

The success of an implant depends on the type of biomaterial used for its fabrication. An ideal implant material should be biocompatible, inert, mechanically durable, and easily moldable. The ability to build patient specific implants incorporated with bioactive drugs, cells, and proteins has made 3D printing technology revolutionary in medical and pharmaceutical fields. A vast variety of biomaterials are currently being used in medical 3D printing, including metals, ceramics, polymers, and composites. With continuous research and progress in biomaterials used in 3D printing, there has been a rapid growth in applications of 3D printing in manufacturing customized implants, prostheses, drug delivery devices, and 3D scaffolds for tissue engineering and regenerative medicine. The current review focuses on the novel biomaterials used in variety of 3D printing technologies for clinical applications. Most common types of medical 3D printing technologies, including fused deposition modeling, extrusion based bioprinting, inkjet, and polyjet printing techniques, their clinical applications, different types of biomaterials currently used by researchers, and key limitations are discussed in detail

Studies on the cytocompatibility, mechanical and antimicrobial properties of 3D printed poly(methyl methacrylate) beads

Osteomyelitis is typically a bacterial infection (usually from Staphylococcus) or, more rarely, a fungal infection of the bone. It can occur in any bone in the body, but it most often affects the long bones (leg and arm), vertebral (spine), and bones of the foot. Microbial success in osteomyelitis is due to their ability to form biofilms which inhibit the wound healing process and increases resistance to anti-infective agents. Also, biofilms do not allow easy penetration of antibiotics into their matrix making clinical treatment a challenge. The development of local antibiotic delivery systems that deliver high concentrations of antibiotics to the affected site is an emerging area of research with great potential. Standard treatment includes antibiotic therapy, either locally or systemically and refractory cases of osteomyelitis may lead to surgical intervention and a prolonged course of antibiotic treatment involving placement of antibiotic-doped beads or spacers within the wound site. There are disadvantages with this treatment modality including insufficient mixing of the antibiotic, lack of uniform bead size, resulting in lower antibiotic availability, and limitations on the antibiotics employed. Thus, a method is needed to address biofilm formations in the wound and on the surface of the surgical implants to prevent osteomyelitis. In this study, we show that all antibiotics studied were successfully doped into PMMA and antibiotic-doped 3D printed beads, disks, and filaments were easily printed. The growth inhibition capacity of the antibiotic-loaded PMMA 3D printed constructs was also demonstrated

The Use of 3D Printing in the Fabrication of Nasal Stents

Nasoalveolar molding of the cleft lip, nose, and alveolar palate has been a successful strategy for the restoration of oronasal function and appearance, but it has some drawbacks. The temporary implant that is inserted before surgical reconstruction is a large appliance requiring numerous adjustments, it can irritate delicate soft tissues, and interfere with the infant’s ability to nurse or feed. In the early post-operative period and for months after cleft lip repair, patients wear standardized silicone stents that come in multiple sizes, but require significant sculpting to fit the unique cleft deformity. Three-dimensional (3D) printing offers the potential of highly personalized and patient-specific treatment. We developed a method that produces a customized 3D printed stent that matches the contours and unique features of each patient and permits modification and adjustments in size and shape as the patient ages. With 3D scanning technology, the device can be designed at the first visit to create an appliance that can be worn sequentially with minimal trauma, does not impede feeding, and a prosthesis that will improve compliance. The device will be worn intraorally to help shape the alveolus, lip, and nose before surgical repair. Furthermore, the stent can be doped with drugs as each patient’s case warrants

Doped Halloysite Nanotubes for Use in the 3D Printing of Medical Devices

Previous studies have established halloysite nanotubes (HNTs) as viable nanocontainers capable of sustained release of a variety of antibiotics, corrosion agents, chemotherapeutics and growth factors either from their lumen or in outer surface coatings. Accordingly, halloysite nanotubes (HNTs) hold great promise as drug delivery carriers in the fields of pharmaceutical science and regenerative medicine. This study explored the potential of 3D printing drug doped HNT constructs. We used a model drug, gentamicin (GS) and polylactic acid (PLA) to fabricate GS releasing disks, beads, and pellets. Gentamicin was released from 3D printed constructs in a sustained manner and had a superior anti-bacterial growth inhibition effect that was dependent on GS doping concentration. While this study focused on a model drug, gentamicin, combination therapy is possible through the fabrication of medical devices containing HNTs doped with a suite of antibiotics or antifungals. Furthermore, tailored dosage levels, suites of antimicrobials, delivered locally would reduce the toxicity of individual agents, prevent the emergence of resistant strains, and enable the treatment of mixed infections