Design and analysis of a reconfigurable discrete pin tooling system for molding of three-dimensional free-form objects

This paper presents the design and analysis of a new reconfigurable tooling for the fabrication of three-dimensional (3D) free-form objects. The proposed reconfigurable tooling system comprises a set of matrices of a closely stacked discrete elements (i.e., pins) arranged to form a cavity in which a free-form object can be molded. By reconfiguring the pins, a single tool can be used in the place of multiple tools to produce different parts with the involvement of much lesser time and cost. The structural behavior of a reconfigurable mold tool under process conditions of thermoplastic molding is studied using a finite element method (FEM) based methodology. Various factors that would affect the tool behavior are identified and their effects are analyzed to optimally design a reconfigurable mold tool for a given set of process conditions. A prototype, open reconfigurable mold tool is developed to present the feasibility of the proposed tooling system. Several case studies and sample parts are also presented in this paper

Designing bio-mimetic variational porosity for tissue scaffolds

Reconstructing or repairing the damaged or diseased tissues with porous scaffolds to restore the mechanical, biological and chemical functions is one of the major tissue engineering strategies. Development of Solid Free Form (SFF) techniques and improvement in biomaterial properties by synergy have provided the leverage to fabricate controlled and interconnected porous scaffold structures. But homogeneous scaffolds with regular porosity do not provide all the biological and mechanical requirements of an ideal tissue scaffold. Thus achieving controllable, continuous, interconnected gradient porosity with reproducible and fabricatable design is critical for successful regeneration of the replaced tissue. In this research, a novel scaffold modeling approach has been proposed to achieve bio-mimetic tissue scaffolds. Firstly, the optimum filament deposition angle has been determined based on the internal heterogeneous regions and their locations. Then an area-weight based approach has been applied to generate the spatial porosity function to determine the filament deposition location for the desired bio-mimetic porosity. The proposed methodology has been implemented using computer simulation. A micro-nozzle biomaterial deposition system driven by NC motion control has been used to fabricate a sample designed structure

Functionally heterogeneous porous scaffold design for tissue engineering

Most of the current tissue scaffolds are mainly designed with homogeneous porosity which does not represent the spatial heterogeneity found in actual tissues. Therefore engineering a realistic tissue scaffolds with properly graded properties to facilitate the mimicry of the complex elegance of native tissues are critical for the successful tissue regeneration. In this work, novel bio-mimetic heterogeneous porous scaffolds have been modeled. First, the geometry of the scaffold is extracted along with its internal regional heterogeneity. Then the model has been discretized with planner slices suitable for layer based fabrication. An optimum filament deposition angle has been determined for each slice based on the contour geometry and the internal heterogeneity. The internal region has been discritized considering the homogeneity factor along the deposition direction. Finally, an area weight based approach has been used to generate the spatial porosity function that determines the filament deposition location for desired biomimetic porosity. The proposed methodology has been implemented and illustrative examples are provided. The effective porosity has been compared between the proposed design and the conventional homogeneous scaffolds. The result shows a significant error reduction towards achieving the biomimetic porosity in the scaffold design and provides better control over the desired porosity level. Moreover, sample designed structures have also been fabricated with a NC motion controlled micro-nozzle biomaterial deposition system

Conformal tissue scaffold with multi-functional porosity for wound healing

In tissue engineering and wound healing, porous scaffolds can stimulate the wound healing process by regenerating the damaged or diseased tissue. But when applied in wound area various forces like bandage, contraction and self weight act upon these visco-elastic scaffold/membrane and cause deformation. As a result, the geometry and the designed porosity change which eventually alters the desired choreographed functionality such as material concentration, design parameters, cytokines distribution over the wound device geometry. In this work, a novel scaffold modelling approach has been proposed that will minimize the change in effective porosity with the designed porosity due to its deformation. First the targeted wound surface model has been extracted and sliced along its depth. Then the height based contours are projected and descritized into functional regions Surface profile for each region have been extracted with contour area weight based slope method. Finally, the filament deposition locations have been generated considering the region profile. Thus the proposed method will give a better functionality of tissue membrane providing predictable material concentration along the wound surface and optimum environment under deformed conditions. The methodology has been implemented using a bi-layer porous membrane via computer simulation. A comparison of the results of effective porosity between the proposed design and conventional design has also been provided. The result shows a significant improvement and control over desired porosity with the proposed method

Multi-functional variational porosity in bone tissue scaffolds

Commonly used homogeneous scaffolds do not capture the intricate spatial material concentration presented in bone internal architecture. On the other hand gradient in porosity along the internal scaffold architecture might contribute for performing diverse mechanical, biological and chemical functions of scaffold. Thus the need for reproducible and fabricatable scaffold design with interconnected and continuous pore and controllable gradient in porosity for tissue regeneration is obvious but is thwarted by design and fabrication limitations. In this work, a novel heterogeneous scaffold modeling approach has been proposed targeting the bio-mimetic porosity design. First, an optimum filament deposition angle has been determined in slices based on the contour geometry of targeted region. And the internal region has been discritized considering the homogeneity factor along the deposition angle. Finally, an area weight based approach has been used to generate the spatial porosity function that determines the filament deposition location for desired bio-mimetic porosity. The proposed methodology has been implemented an illustrative examples using computer simulation. A comparison result of effective porosity has been presented between proposed design model and conventional fixed filament distance scaffolds respectively. The result shows a significant error reduction towards the achieving bio-mimetic scaffold design concept and provides more control over the desired porosity level. Moreover, the resultant model can easily be fabricated with simple SFF processes

Modeling of multifunctional deformable porous scaffolds for soft tissue engineering

Porous membranes/scaffolds such as guided tissue regeneration (GTR) membranes, cell sheets, tissue matrices or polymeric meshes are being widely used in soft tissue engineering to regenerate damaged, diseased tissue or wound. These membranes are mostly regular porous structures with repeating internal architecture. When they are applied onto wound area, various forces caused by bandage, contraction and self weight might cause deformation. As a result, the geometry and the designed porosity changes which eventually alters the desired choreographed functionality. To avoid the negative effect cause by such deformation and its associated consequences, a novel design methodology has been proposed to determine and include the resultant deformation. The proposed design will minimize the variation in effective porosity while ensuring its surface conformity. Thus the proposed design will provide a better functionality by providing both structural integrity and proper biological properties. The proposed methodology has been implemented and results will be shown with illustrative examples. Also a comparison study showing effective porosity for both the proposed method and conventional regular porosity will be presented for a free-form surface mimicking a wound

Multi-function based modeling of 3D heterogeneous wound scaffolds for improved wound healing

This paper presents a new multi-function based modeling of 3D heterogeneous porous wound scaffolds to improve wound healing process for complex deep acute or chronic wounds. An imaging-based approach is developed to extract 3D wound geometry and recognize wound features. Linear healing fashion of the wound margin towards the wound center is mimicked. Blending process is thus applied to the extracted geometry to partition the scaffold into a number of uniformly gradient healing regions. Computer models of 3D engineered porous wound scaffolds are then developed for solid freeform modeling and fabrication. Spatial variation over biomaterial and loaded bio-molecule concentration is developed based on wound healing requirements. Release of bio-molecules over the uniform healing regions is controlled by varying their amount and entrapping biomaterial concentration. Thus, localized controlled release is developed to improve wound healing. A prototype multi-syringe single nozzle deposition system is used to fabricate a sample scaffold. Proposed methodology is implemented and illustrative examples are presented in this paper

3D hybrid wound devices for spatiotemporally controlled release kinetics

This paper presents localized and temporal control of releasekinetics over 3-dimensional (3D) hybridwounddevices to improve wound-healing process. Imaging study is performed to extract wound bed geometry in 3D. Non-Uniform Rational B-Splines (NURBS) based surface lofting is applied to generate functionally graded regions. Diffusion-based releasekinetics model is developed to predict time-based release of loaded modifiers for functionally graded regions. Multi-chamber single nozzle solid freeform dispensing system is used to fabricate wounddevices with controlled dispensing concentration. Spatiotemporal control of biological modifiers thus enables a way to achieve target delivery to improve wound healing

Optimized normal and distance matching for heterogeneous object modeling

This paper presents a new optimization methodology of material blending for heterogeneous object modeling by matching the material governing features for designing a heterogeneous object. The proposed method establishes point-to-point correspondence represented by a set of connecting lines between two material directrices. To blend the material features between the directrices, a heuristic optimization method developed with the objective is to maximize the sum of the inner products of the unit normals at the end points of the connecting lines and minimize the sum of the lengths of connecting lines. The geometric features with material information are matched to generate non-self-intersecting and non-twisted connecting surfaces. By subdividing the connecting lines into equal number of segments, a series of intermediate piecewise curves are generated to represent the material metamorphosis between the governing material features. Alternatively, a dynamic programming approach developed in our earlier work is presented for comparison purposes. Result and computational efficiency of the proposed heuristic method is also compared with earlier techniques in the literature. Computer interface implementation and illustrative examples are also presented in this paper

Bioadditive manufacturing of hybrid tissue scaffolds for controlled release kinetics

Development of engineered tissue scaffolds with superior control over cell-protein interactions is still very much infancy. Advancing through heterogeneous multifold scaffolds with controlled release fashion enables synchronization of regenerating tissue with the release kinetics of loaded biomolecules. This might be an engineering challenge and promising approach for improved and efficient tissue regeneration. The most critical limitations: the selection of proper protein(s) incorporation, and precise control over concentration gradient and timing should be overcome. Hence, tissue scaffolds need to be fabricated in a way that proteins or growth factors should be incorporated and released in a specific spatial and temporal orientation to mimic the natural tissue regeneration process. Spatial and temporal control over heterogeneous porous tissue scaffolds can be achieved by controlling two important parameters: (i) internal architecture with enhanced fluid transport, and (ii) distribution of scaffold base material and loaded modifiers. In this research, heterogeneous tissue scaffolds are designed considering both the parameters. Firstly, the three-dimensional porous structures of the scaffold are geometrically partition into functionally uniform porosity regions and controlled spatial micro-architecture has been achieved using a functionally gradient porosity function. The bio-fabrication of the designed internal porous architecture has been performed using a single nozzle bioadditive manufacturing system. The internal architecture scheme is developed to enhance fluid transport with continuous base material deposition Next, the hybrid tissue scaffolds are modeled with varying material characteristics to mediate the release of base material and enclosed biological modifiers are proposed based on tissue engineering requirements. The hybrid scaffolds are fabricated for spatial control of biomolecules and base material to synchronize the release kinetics with tissue regeneration. A pressure-assisted multi-chamber single nozzle bioadditive manufacturing system is used to fabricate hybrid scaffolds