Engineering design of artificial vascular junctions for 3D printing

Vascular vessels, including arteries, veins and capillaries, are being printed using additive manufacturing technologies, also known as 3D printing. This paper demonstrates that it is important to follow the vascular design by nature as close as possible when 3D printing artificial vascular branches. In previous work, the authors developed an algorithm of computational geometry for constructing smooth junctions for 3D printing. In this work, computational fluid dynamics (CFDs) is used to compare the wall shear stress and blood velocity field for the junctions of different designs. The CFD model can reproduce the expected wall shear stress at locations remote from the junction. For large vessels such as veins, it is shown that ensuring the smoothness of the junction and using smaller joining angles as observed in nature is very important to avoid high wall shear stress and recirculation. The issue is however less significant for capillaries. Large joining angles make no difference to the hemodynamic behavior, which is also consistent with the fact that most capillary junctions have large joining angles. The combination of the CFD analysis and the junction construction method form a complete design method for artificial vascular vessels that can be 3D printed using additive manufacturing technologies

The effect of geometry on mechanical properties of biodegradable polylactic-acid tensile-test specimens by material extrusion

Additive manufactured biomedical devices have been widely used in the biomedical fields due to the development of biomaterials and manufacturing techniques. Biodegradable Polylactic Acid-based polymers are the most common material that can be manufactured using material extrusion, one of the most widely known additive manufacturing methods. However, medical grade polymers are too expensive for degradation studies with common tensile specimens. Therefore, this paper aims to reduce the volume of the material used for manufacturing tensile specimen by introducing a new tensile specimen, Micro-X tensile specimen, developed for steel. Young’s Modulus and Ultimate Tensile Strength of micro-X tensile specimens were compared with the ASTM D1708 standard specimens. The experimental results showed that there is no significant difference in terms of mechanical properties. Furthermore, the micro-X tensile specimen was reduced the volume and as well as the cost by approximately 91% in comparison to ASTM D1708 standard tensile specimen

Mechanical behaviours and mass transport properties of bone-mimicking scaffolds consisted of gyroid structures manufactured using selective laser melting

Bone scaffolds created in porous structures manufactured using selective laser melting (SLM) are widely used in tissue engineering, since the elastic moduli of the scaffolds are easily adjusted according to the moduli of the tissues, and the large surfaces the scaffolds provide are beneficial to cell growth. SLM-built gyroid structures composed of 316L stainless steel have demonstrated superior properties such as good corrosion resistance, strong biocompatibility, self-supported performance, and excellent mechanical properties. In this study, gyroid structures of different volume fraction were modelled and manufactured using SLM; the mechanical properties of the structures were then investigated under quasi-static compression loads. The elastic moduli and yield stresses of the structures were calculated from stress-strain diagrams, which were developed by conducting quasi-static compression tests. In order to estimate the discrepancies between the designed and as-produced gyroid structures, optical microscopy and micro-CT scanner were used to observe the structures’ micromorphology. Since good fluidness is conducive to the transport of nutrients, computational fluid dynamics (CFD) values were used to investigate the pressure and flow velocity of the channel of the three kinds of gyroid structures. The results show that the sizes of the as-produced structures were larger than their computer aided design (CAD) sizes, but the manufacturing errors are within a relatively stable range. The elastic moduli and yield stresses of the structures improved as their volume fractions increased. Gyroid structure can match the mechanical properties of human bone by changing the porosity of scaffold. The process of compression failure showed that 316L gyroid structures manufactured using SLM demonstrated high degrees of toughness. The results obtained from CFD simulation showed that gyroid structures have good fluidity, which has an accelerated effect on the fluid in the middle of the channel, and it is suitable for transport nutrients. Therefore, we could predict the scaffold's permeability by conducting CFD simulation to ensure an appropriate permeability before the scaffold being manufactured. SLM-built gyroid structures that composed of 316L stainless steel were suitable to be designed as bone scaffolds in terms of mechanical properties and mass-transport properties, and had significant promise

Interfacial fracture of 3D-printed bioresorbable polymers

A micro specimen for tensile testing was designed with two primary aims: (i) to characterise interface fracture behaviour between fused 3D-printed polymer filaments; and (ii) to minimise material use of high-cost medical-grade polymer since a high number of specimens are required for time-series studies (e.g. polymer degradation). Polylactide specimens were fabricated on an extrusion 3D-printer as a single-filament-wide wall. The widths of filaments were set individually, with a custom machine-control code, to achieve a higher width in the grip sections of specimens and a narrower width in their gauge section. On average, the interface between filaments was 114 µm narrower than the widest point of the filaments. Each specimen was tested in the build direction to determine the interfacial strength between 3D-printed layers. Optical microscopy was employed to characterise geometry of specimens and fracture surfaces. Samples fractured in the gauge section and the fracture surface demonstrated brittle characteristics. The specimens utilised an order of magnitude less material than ASTM D638 samples, whilst maintaining repeatability for tensile strength similar to that in other studies. The average strength was 49.4 MPa, which is comparable to data in the literature. Further optimisation of the specimen design and 3D printing strategy could realise greater reductions in material use

Multiscale modeling for the heterogeneous strength of biodegradable polyesters

A heterogeneous method of coupled multiscale strength model is presented in this paper for calculating the strength of medical polyesters such as polylactide (PLA), polyglycolide (PGA) and their copolymers during degradation by bulk erosion. The macroscopic device is discretized into an array of mesoscopic cells. A polymer chain is assumed to stay in one cell. With the polymer chain scission, it is found that the molecular weight, chain recrystallization induced by polymer chain scissions, and the cavities formation due to polymer cell collapse play different roles in the composition of mechanical strength of the polymer. Therefore, three types of strength phases were proposed to display the heterogeneous strength structures and to represent different strength contribution to polymers, which are amorphous phase, crystallinity phase and strength vacancy phase, respectively. The strength of the amorphous phase is related to the molecular weight; strength of the crystallinity phase is related to molecular weight and degree of crystallization; and the strength vacancy phase has negligible strength. The vacancy strength phase includes not only the cells with cavity status but also those with an amorphous status, but a molecular weight value below a threshold molecular weight. This heterogeneous strength model is coupled with micro chain scission, chain recrystallization and a macro oligomer diffusion equation to form a multiscale strength model which can simulate the strength phase evolution, cells status evolution, molecular weight, degree of crystallinity, weight loss and device strength during degradation. Different example cases are used to verify this model. The results demonstrate a good fit to experimental data

Degradation models for polyesters and their composites

Intensive studies are being carried out to use devices made of bioresorbable polymers inside the human body to provide various temporary functions. Typical examples include scaffolds for tissue engineering, fixation screws for broken bones and drug-loaded matrices for controlled-release. The development is entirely based on trial and error. The degradation rate strongly depends on the shape and size of the devices, making it difficult to transfer experience from one device to another. The degradation time ranges from weeks to years; animal and ultimately human trials have to be carried out, making the trial and error approach time-consuming and expensive. The entire field would benefit enormously from mathematical models capable of predicting the degradation and property change of the devices. This PhD project will develop such models as following: a) A multi-scale model for degradation of bioresorbable polyesters was developed. Events that occur at the molecular scale are modelled at the molecular scale using the kinetic Monte Carlo schemes while events that occur at the device scale are modelled using macroscopic diffusion model. b) A phenomenological model for simultaneous crystallisation and biodegradation of biodegradable polymers was developed. This model completed the degradation theory developed by Wang et al. at University of Leicester. c) The model in (b) was improved and applied to the analysis of accelerated degradation data. Temperature effects were taking into account by using Arrhenius relations. d) A model for the biodegradation of composite materials made of polyesters and calcium phosphates was developed. A calcium phosphate effectiveness map is established to show the conditions under which incorporating calcium phosphates into polyesters is effective, saturated or ineffective. f) A phase field model was developed for drug release from a swelling Hydroxypropyl methylcellulose matrix. This model can be readily extended to full three dimensional problems

A Model for Simultaneous Crystallisation and Biodegradation of Biodegradable Polymers.

This paper completes the model of biodegradation for biodegradable polymers that was previously developed by Wang et al. (Wang Y, Pan J, Han X, Sinka, Ding L. A phenomenological model for the degradation of biodegradable polymers. Biomaterials 2008;29:3393-3401). Crystallisation during biodegradation was not considered in the previous work which is the topic of the current paper. For many commonly used biodegradable polymers, there is a strong interplay between crystallisation and hydrolysis reaction during biodegradation – the chain cleavage caused by the hydrolysis reaction provides an extra mobility for the polymer chains to crystallise and the resulting crystalline phase becomes more resistant to further hydrolysis reaction. This paper presents a complete theory to describe this interplay. The fundamental equations in the Avrami’s theory for crystallisation are modified and coupled to the diffusion-reaction equations that were developed in our previous work. The mathematical equations are then applied to three biodegradable polymers for which long term degradation data are available in the literature. It is shown that the model can capture the behaviour of the major biodegradable polymers very well

Role of Free Radicals/Reactive Oxygen Species in MeHg Photodegradation: Importance of Utilizing Appropriate Scavengers

A variety of free radicals (FR)/reactive oxygen species (ROS) have been proposed to dominate methylmercury (MeHg) photodegradation, primarily based on the results of FR/ROS scavenger addition experiments. However, in addition to eliminating FR/ROS, the added scavengers may also affect the experimental results by altering some water chemical properties, resulting in a misleading assessment of the importance of FR/ROS. In this study, 20 common FR/ROS scavengers were evaluated in terms of their influence on light absorbance, pH, MeHg analysis, MeHg-dissolved organic matter (DOM) complexation, and the scavenger-induced degradation of MeHg. Only nine scavengers were identified to be appropriate for investigating MeHg photodegradation. By utilizing these appropriate scavengers, direct photodegradation of MeHg-DOM complexes was found to be the major pathway of MeHg photodegradation in Laoshan Reservoir water and Stone Old Beach seawater. In contrast, MeHg photodegradation in Ink River water primarily occurs through both ·OH and ³DOM* mediated indirect pathways and direct photodegradation of MeHg-DOM complexes. The diverse pathways of MeHg photodegradation in the tested water may be due to differences in water chemical properties. A severe overestimation of the role of FR/ROS was observed when several improper but commonly used scavengers were adopted, highlighting the necessity of utilizing appropriate scavengers

Mechanical and hydrolytic properties of thin polylactic acid films by fused filament fabrication

Thin polymeric films are widely used as medical applications such as cell culture, stent, drug delivery and mechanical fixation. One of the most commonly used materials is polylactic acid (PLA) - a material, which is non-toxic, biodegradable and biocompatible. Fused filament fabrication (FFF) is a preferable additive manufacturing technique to manufacture polymers, where PLA is one of the most common materials. FFF is a promising technique for customised biomedical applications due to its relatively low cost and geometrical flexibility where biomedical applications are patient tailored. This study is the first to consider FFF monolayered thin films of PLA in terms of mechanical and hydrolytic properties at 37 °C in vitro degradation. Throughout degradation, the reduction in mechanical properties was examined by analysing molecular weight and thermal properties. FFF monolayered PLA underwent autocatalytic bulk degradation with no proof of significant mass loss. Young’s modulus, ultimate tensile strength and molecular weight reduced by approximately 60%, 86%, and 80% after 280 days, respectively, while the degree of crystallinity increased by 143% in comparison to benchmark thin films at day 0. It was found that the decrease in mechanical properties was more sensitive to the increase in crystallinity in the early stage of the degradation, while the molecular weight was more dominant in the late stage of the degradation. This study provides practical information in terms of mechanical properties to support medical device designers in a range of potential end-use biomedical applications to achieve safe functional products over the required degradation lifetime

Establishing in-process inspection requirements for material extrusion additive manufacturing [poster]

Establishing in-process inspection requirements for material extrusion additive manufacturing [poster