JP7365020B2 - Method for manufacturing objects with gel - Google Patents

Description

The present invention relates to a method for manufacturing objects containing gel.

BACKGROUND ART Medical models have been proposed for practice purposes such as surgical operations. For example, Patent Document 1 proposes a technique for creating a medical model by using a gel material made of a polymer as ink of a 3D printer and modeling based on 3D data of each patient's organs.

JP2017-026680A

However, from the viewpoint of practice for surgical operations, etc., modeling based on 3D data of each patient's organs is not only time-consuming but also seems to be costly. This is true not only in the medical field but in any field.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a method for producing an object containing gel, an object containing gel, and a molding material that can be manufactured easily and at low cost.

In order to achieve the above object, the method of manufacturing an object having gel according to the present invention uses a 3D printer to improve one or more physical properties selected from thermal conductivity, surface roughness, hardness, or elasticity, or color. The process of creating a mold by arranging different resin materials for each part of the mold, and molding a molding material that has thermoreversible, thermosetting, or cation-reactive gelling properties. A step of supplying one or more molding materials to a mold to obtain a molded product , or a step of supplying one or more molding materials having gelation properties of thermoreversibility, thermosetting, or cationic reactivity, and having different physical properties for each part of the molded product. and a step of molding using a mold to obtain a molded product.

Here, the molded product may be a molded product imitating biological tissue.

Further, a molded product imitating a living tissue different from the molded product, or a part or all of a surgical material may be embedded in the molded product.

Further, part or all of a molded article imitating a living tissue or a surgical material may be manufactured using a plurality of resin materials having different physical properties or colors.

In addition, a molded article imitating a living tissue different from the molded article or a surgical material may be a shaped article formed using a 3D printer and/or a second molded article formed using a mold. It is also good to have.

In addition, the molding materials include agar, carrageenan, farcellan, gelatin, xanthan gum, cassia gum, guar gum, tara gum, locust bean gum, fenugreek gum, glucomannan, tamarind gum, gellan gum, native gellan gum, alginate, pectin, curdlan, starch, It may contain one or more selected from egg white, processed egg white, polyvinyl alcohol, whey protein material, gelatin enzyme reaction product, tamarind gum enzyme reaction product, and psyllium seed gum.

Further, a molded product imitating a living tissue different from the molded product, or a surgical material, and the molded product may each have different colors that can be visually distinguished.

Further, the object having gel may be an object having gel for practicing surgery or learning how to operate a medical robot.

In order to achieve the above object, the gel-containing object of the present invention comprises a molding material having one or more of the following gelling properties: thermoreversible, thermosetting, and cation-reactive. It has a molded article in which a gel is placed that has physical properties that differ depending on the site, and a surgical material or a body tissue imitating a different body than the molded article, which is embedded in whole or in part in the molded article.

Here, in an aqueous solution containing a hydrogelling agent, the gel transitions from a sol to a gel. One or more of gel-like coating materials in which the difference is in the range of 1 to 200 mPa・s, or gel-like coating materials in which the transition from sol to gel occurs via monovalent and/or divalent cations. It is good also as having at least one layer or more.

In addition, the gel is native gellan gum, κ-carrageenan, or agar, and the gel-like coating material in which the transition from sol to gel is performed via one or more monovalent or divalent cations is sodium alginate or potassium alginate. , ammonium alginate, LM pectin, deacylated gellan gum, sodium type κ carrageenan, and the monovalent and/or divalent cation is one or more of sodium, potassium, calcium, and magnesium. It may be a good thing.

Alternatively, the molded product may be air-filled.

In order to achieve the above object, the 3D printer of the present invention is used to print one or more parts selected from thermal conductivity, surface roughness, hardness, or elasticity using a plurality of resin materials having different physical properties or colors. The molding materials used to mold the gel are agar, carrageenan, farcellan, gelatin, xanthan gum, cassia gum, guar gum, tara gum, locust bean gum, fenugreek gum, glucomannan, tamarind gum, gellan gum, native gellan gum. , alginate, pectin, curdlan, starch, egg white, processed egg white, polyvinyl alcohol, whey protein material, gelatin enzyme reaction product, tamarind gum enzyme reaction product, and psyllium seed gum.

According to the present invention, it is possible to provide a method for manufacturing an object having gel, an object having gel, and a molding material that can be manufactured easily and at low cost.

FIG. 3 is a flow diagram of a method for manufacturing a mold according to the first embodiment. FIG. 2 is a perspective view of a set of molds used in the first embodiment. It is a photograph substituted for a drawing of a set of molds used in the first embodiment. FIG. 2 is a perspective view showing a closed state of a set of molds according to the first embodiment. FIG. 3 is a schematic diagram showing a state of molding according to the first embodiment. FIG. 3 is a schematic cross-sectional view showing a state in which a molded article is placed in a transfer recess of the mold according to the first embodiment. FIG. 7 is an external view of a blood vessel according to a second embodiment. FIG. 7 is an external view of a liver organ model according to a second embodiment. It is a photograph substituted for a drawing of a set of molds for a liver according to a second embodiment. It is a photograph substituted for a drawing in which an organ model is fitted into a transfer recess of a set of molds for a liver according to a second embodiment. It is a photograph substituted for a drawing of an organ model according to a second embodiment. FIG. 7 is a schematic cross-sectional view showing a state in which a water-soluble resin is placed in a molded article according to a third embodiment. 13 is a schematic cross-sectional view showing a state in which a cavity is formed in a molded product by melting the water-soluble resin from the state shown in FIG. 12. FIG. FIG. 7 is a schematic cross-sectional view showing a state in which a water-soluble resin is placed in a molded product according to a modification of the third embodiment. FIG. 15 is a schematic cross-sectional view showing a state in which passages are formed in the molded product by melting the water-soluble resin from the state shown in FIG. 14; FIG. 7 is a perspective view of a mold according to a fourth embodiment. FIG. 7 is a perspective view of a mold according to a fourth embodiment. FIG. 16 is a sectional view taken along line AA in FIG. 16; It is a flowchart of the manufacturing method of the shaping|molding die based on 4th Embodiment. FIG. 7 is a manufacturing flow diagram of a blood vessel according to a fourth embodiment. FIG. 3 is a perspective view showing how blood vessels are placed in the mold before the gel is placed in the mold. It is a perspective view of a blood vessel showing a modification of the fourth embodiment.

Hereinafter, a plurality of embodiments will be described based on the drawings. Here, the gel is something as soft as, for example, an organ or human skin. Moreover, "an object having a gel" refers to an object containing at least a simple gel. Furthermore, in this specification, "molding" refers to making a material into a certain shape using a mold, etc., and refers to making something with a shape using a three-dimensional printer (3D printer), etc., which will be described later. It's called "shaping." Furthermore, in this specification, things expressed as "hard" have a Shore hardness of 95 or more, and things expressed as "soft", such as gel, have a Shore hardness of less than 95. Furthermore, in this specification, a product formed by molding a "gel" with a mold is referred to as a "molded product", and in the second embodiment, a molded product imitating a biological tissue (for convenience, hereinafter referred to as "a molded product imitating a biological tissue") is referred to as a "molded product". An object created using a 3D printer is called a ``modeled object.'' Furthermore, in the second embodiment, an object made from a mold that imitates living tissue is referred to as a "second molded object." Furthermore, in this specification, the term "resin material" includes a single resin, a mixture of different resins, and a material in which a resin is mixed with metal, ceramic, or the like.

(Contents of the method for producing an object having gel according to the first embodiment)
Hereinafter, a method for manufacturing a gel-containing object according to the first embodiment will be described with reference to the drawings. FIG. 1 is a flowchart of a method for manufacturing a mold according to a first embodiment. FIG. 2 is a perspective view of a set of molds used in the first embodiment. FIG. 3 is a photograph substituted for a drawing of a set of molds used in the first embodiment. FIG. 4 is a perspective view showing a closed state of a set of molds according to the first embodiment. FIG. 5 is a schematic diagram showing the state of molding according to the first embodiment.

First, step S shown in FIG. 1 is performed. Step S is a step of forming a mold onto which the shape of the object is transferred using a 3D printer. A 3D printer is referred to as a three-dimensional printing device, three-dimensional printer, three-dimensional modeling machine, or the like. Furthermore, a 3D printer prints and manufactures 3D objects based on three-dimensional CAD (computer-aided design) data. In addition, when printing with a 3D printer, for example, when printing, a photocurable resin material such as an ultraviolet curable resin material is formed one layer at a time, and the resin material layer is layered by repeating the operation of curing the resin material by irradiating ultraviolet rays each time. , and gradually print, or form, a three-dimensional shape. This photocurable resin includes a resin that is cured by light such as a black light or a laser, in addition to a resin that is cured by ultraviolet light. This also applies to the photocurable resin for 3D printers used in the second, third, and fourth embodiments.

Part or all of the three-dimensional CAD data of an object can be obtained by scanning the object with a three-dimensional scanner, for example. A non-contact type 3D scanner mainly uses light, or electromagnetic waves, to irradiate an object with a laser or the like and analyze the reflected light to obtain 3D CAD data. Further, to obtain three-dimensional CAD data of an organ model, an MRI (Magnetic Resonance Imaging) or CT (Computed Tomography) scanner or the like can be used. In addition, part or all of the three-dimensional CAD data can be obtained by modeling by operating three-dimensional CAD software on a computer without using a three-dimensional scanner, MRI, CT scanner, or the like.

Then, three-dimensional CAD data of a set of molds 1a and 1b is created by transferring the shape of the object. This "object" is a human heart. Three-dimensional CAD data (A) of the human heart is created by scanning the human heart with an MRI or CT scanner (S1). Then, three-dimensional CAD data (B1, B2) of each of the pair of molds 1a, 1b, other than the transfer portions 2a, 2b (described later), are created one by one (S2). The three-dimensional CAD data (B1, B2) are created by operating three-dimensional CAD software on a computer.

Then, the three-dimensional CAD data (A) of the human heart is processed (S3). There are two processing points. The first processing point is processing to reverse the unevenness of the three-dimensional CAD data (A) of the human heart. This is because, in order to mold a human heart using a pair of molds 1a and 1b, the unevenness of the three-dimensional CAD data (A) needs to be reversed. The second processing point is to distribute the shape of the human heart to a set of molds 1a and 1b, by reversing the unevenness of the three-dimensional CAD data (A) of the human heart and cutting it by about half. This is processing to separate the data into two three-dimensional CAD data, A1 and A2 (S3). These processes are also performed by operating three-dimensional CAD software on a computer.

Then, the three-dimensional CAD data (A1) and the three-dimensional CAD data (B1) are combined or added (S4). Similarly, the three-dimensional CAD data (A2) and the three-dimensional CAD data (B2) are combined or added (S4). That is,
A1+B1→C1
A2+B2→C2
These data operations are performed to obtain three-dimensional CAD data (C1) and three-dimensional CAD data (C2). The three-dimensional CAD data (C1) is the three-dimensional CAD data of the mold 1a, and the three-dimensional CAD data (C2) is the three-dimensional CAD data of the mold 1b. These operations are also performed by operating three-dimensional CAD software on a computer.

Then, based on the three-dimensional CAD data (C1, C2) of the set of molds 1a, 1b, the set of molds 1a, 1b are respectively modeled using a 3D printer (S5). Process S is now completed. Other methods of creating a mold formed using a 3D printer may also be used. This mold is made of a resin material and consists of a set of molds 1a and 1b. One of the molds 1a has a transfer recess 2a into which the shape of about half of the human heart is transferred, and the other mold 1b has the shape of the remaining half of the human heart described above. There is a transfer recess 2b whose shape has been transferred. The transfer recesses 2a, 2b are recessed relative to the reference surfaces 3a, 3b that are in close contact with each other when the pair of molds 1a, 1b are closed.

One mold 1a has recesses 4a, 4b, and 4c in the area where the shape of the "object" is not transferred, and the other mold 1b has recesses 4a, 4b, and 4c in the area where the shape of the "object" is not transferred. There are protrusions 5a, 5b, 5c that can be fitted into the recesses 4a, 4b, 4c. By fitting the recess 4a and the projection 5a, the recess 4b and the projection 5b, and the recess 4c and the projection 5c, the transfer recess 2a and the transfer recess 2b are aligned. When the positions are aligned in this way and the pair of molds 1a and 1b are in a closed state and the reference surfaces 3a and 3b are in close contact with each other, the two transfer recesses 2a and 2b form. The created space can be made to have the exact shape of a human heart.

When the pair of molds 1a, 1b is open, grooves 6a, 6b for supplying molding material from the outside to the transfer recesses 2a, 2b are provided in each of the molds 1a, 1b. When the pair of molds 1a, 1b is closed, the two grooves 6a, 6b serve as paths, forming a molding material supply path 7 for supplying molding material from the outside to both the transfer portions 2a, 2b.

Next, a molding material is prepared and molded using a pair of molds 1a and 1b. The molding material has thermoreversible gelling properties. The specific molding material is water mixed with agar. The mixing ratio is 20 g of powdered agar to 1000 g of water. After heating and melting the agar to make the agar into a sol state, a molding material is supplied from the molding material supply path 7 with the aforementioned pair of molds 1a and 1b closed. The sol-like agar aqueous solution, which is the molding material, has a low viscosity at about 60° C. and can penetrate into the fine parts of the transfer recesses 2a and 2b. In addition, when the sol-like agar aqueous solution is in the closed state and the reference surfaces 3a and 3b are in close contact with each other, the sol-like agar aqueous solution is There was almost no leakage from the gaps.
The molding material is selected from hydrocolloids that have the property of gelling due to thermoreversibility, thermosetting, or cationic reactivity.
Thermoreversible gels have the property of melting when heated and solidifying when cooled, such as agar, carrageenan, farcellan, gelatin, xanthan gum, cassia gum, guar gum, tara gum, locust bean gum, fenugreek gum, glucomannan, tamarind gum, Examples include one or more materials selected from gellan gum, native gellan gum, and starch. Among these, for example, xanthan gum has the property of gelling when combined with one or more of cassia gum, tara gum, locust bean gum, and psyllium seed gum.
Thermosetting gels have the property of being dissolved in water or lukewarm water and solidified by heating, and include, for example, curdlan, egg white, processed egg white, and the like.
Gels with cationic reactivity have the property of solidifying by adding cations such as calcium ions to a dissolved aqueous solution to form a crosslinked structure, and include alginates (sodium alginate, potassium alginate, etc.), pectin, guar gum, polyvinyl alcohol, etc. is exemplified.
A hydrocolloid having the property of gelling due to thermoreversibility, thermosetting property, or cationic reactivity may be blended with one or more selected from the above-mentioned materials, as long as it does not inhibit gelation.
In the case of powder, these materials may be blended and mixed in advance, or the mixed powder may be dissolved to form a molding liquid. Preferably, they are weighed and packaged for ease of use. If a thermoreversible molding fluid (referring to a liquid molding material or molded product; the same applies hereinafter) is stored at room temperature and has become a gel, it is used after being heated and remelted during molding.
Cation-reactive molding fluids are used in which cations such as calcium are added at the same time during molding. Furthermore, a preservative such as methylparaben or ethylparaben can be added as necessary to prevent the molded product from spoiling.
It is preferable that the physical properties of the object having a gel imitating a living tissue be matched to each living tissue. For this purpose, the physical properties of hydrocolloids that have gelation properties due to thermoreversibility, thermosetting properties, or cationic reactivity are important.
Shore hardness is often used as the hardness of industrial materials used in conventional 3D printers. Although the Shore hardness of the present invention varies depending on each biological tissue, it can be expressed as, for example, a rubber Shore hardness of A10 or less.
On the other hand, in the present invention, the rheological properties of a gel-like material can be measured using breaking strength and breaking strain using a texture analyzer or rheometer, making it possible to imitate living tissue with high precision.
The breaking strength is the load when stress is applied to the gel of the present invention and it breaks, and the breaking strain can be expressed as the deformation distance until the gel of the present invention is stressed and breaks. Materials for objects containing the gel of the present invention can be combined in accordance with each living tissue.

A first gel-like film material that can be used as a gel-containing object in this embodiment will be described. In an aqueous solution containing a hydrogelling agent, the difference in solution viscosity between the solution viscosity 5°C higher than the temperature at which the sol transitions to gel (gelling transition temperature) and the solution viscosity 20°C higher than the gelling transition temperature is 1~ A gel-like coating material that is in the range of 200 mPa・s and has an extremely high gel forming ability, reaching the desired gel strength at a temperature several degrees lower than the gel transition temperature, and after that, the amount of change in gel strength due to temperature changes is small. Examples include native gellan gum, κ carrageenan, agar, xanthan gum and galactomannan, xanthan gum and glucomannan, and deacylated gellan gum, but native gellan gum, κ carrageenan, and agar are preferred because they are easy to work with and have good liquid properties.
A film material that can be preferably used as a gel-containing object in this embodiment will be described. In order for the film to be formed uniformly and to an appropriate thickness, the conditions required for the film material are as follows:
(1) When applying the film, the viscosity of the hydrocolloid solution (sol) with gelling power is low. If the viscosity is high, the film will be thick, making it impossible to obtain the desired thin film.
(2) The difference between the sol viscosity near the temperature at which it is applied and the sol viscosity near the temperature at which it transitions from sol to gel (gelation transition temperature) is small and the viscosity is low (in order to quickly gel after application) (This is because it is preferable that the coating be performed at a temperature as close as possible to the gelation transition temperature.)
(3) After a hydrocolloid solution (sol) with gelling power is applied, it quickly gels and solidifies.
Examples include.
Alternatively, a hydrocolloid solution (sol) having gelling power that instantly gels by reacting with monovalent or divalent cations may be used.
in particular,
For the first gel-like coating material, in a hydrocolloid aqueous solution with gelling power, the difference between the solution viscosity 5°C higher than the gelling transition temperature and the solution viscosity 20°C higher than the gelling transition temperature is 1 to 200 mPa・s. range, and has an extremely high gel-forming ability, reaching the desired gel strength at a temperature several degrees lower than the gel transition temperature, and thereafter the gel strength changes little due to temperature changes.Native gellan gum, Examples include κ-carrageenan and agar.
Examples of the second gel-like coating material include gel-like coating materials characterized in that the transition from sol to gel is carried out via monovalent or divalent cations, such as sodium alginate, potassium alginate, Examples include ammonium alginate, LM pectin, deacylated gellan gum, Azotobacter vinelang gum, and sodium type kappa carrageenan.
A film material having at least one layer of such a film is a film material that can be preferably used as the gel-containing object in this embodiment.

A second gel-like film material that can be used as a gel-containing object in this embodiment will be described. Examples of gel-like coating materials characterized in that the transition from sol to gel is carried out via monovalent or divalent cations include sodium alginate, potassium alginate, ammonium alginate, LM pectin, deacylated gellan gum, and azotobacterine. Ranji gum, sodium type kappa carrageenan.
Here, sodium alginate, potassium alginate, ammonium alginate, LM pectin, deacylated gellan gum, and Azotobacter vinelang gum react with calcium ions to form a gel. Deacylated gellan gum reacts with calcium ions, sodium ions, potassium ions, magnesium ions, etc. to form a gel. Sodium-type κ-carrageenan reacts with potassium, sodium, calcium, magnesium, etc. to form a gel.

The purpose of providing the film is to imitate the serosa on the surface of an organ when the object containing the gel of the present invention is used for surgical practice or for learning how to operate a medical robot.
With the first gel-like film material, the method for forming a film is to (1) impregnate an object with a gel in an aqueous solution containing a hydrogelling agent and pull it up; (2) apply a hydrogelling agent to the object and pull it up. (3) Spraying an aqueous solution containing a hydrogelling agent.
In the second gel-like film material, (1) an aqueous solution containing a hydrogelling agent is attached to an object having a gel by dipping, coating, spraying, etc., and then one or more monovalent or divalent cations are applied. (2) attaching or impregnating an object with a gel with one or more monovalent or divalent cations by dipping, coating, spraying, etc., and then forming a hydrogel; There are methods of attaching the agent by dipping, coating, spraying, etc. with an aqueous solution containing the agent. Alternatively, a method may also be used in which one or more of monovalent or divalent substances are dissolved and mixed during the production of an object having a gel, and after molding, an aqueous solution containing a hydrogelling agent is applied by dipping, coating, spraying, etc.
As the first gel-like coating material and the second gel-like coating material, the hydrogelling agent solution may contain saccharides, emulsifiers, polyols, hydrocolloids other than the above, minerals, pigments, fibers, etc. good. The sugars include monosaccharides, disaccharides, oligosaccharides, dextrins, sugar alcohols thereof, and emulsifiers that are commonly used and are not particularly limited. Examples of polyols include glycerin, propylene glycol, butylene glycol, and the like. Hydrocolloids include starch, gelatin, guar gum, locust bean gum, tara gum, fenugreek gum, cassia gum, HM pectin, tamarind gum, and the like. Minerals, pigments, and fibers are not particularly important.

In addition, by incorporating gas into the molded product (by making it aerated), it is possible to make a soft molded product with a lower specific gravity than that which is not made to contain air. The size (diameter) of the gas is not particularly limited, but may be from a nanoscale microscopic thing called a nanobubble to a large one of about 5 mm.
Methods for aerating the molding material solution include adding a foaming agent such as an emulsifier, protein, or peptide to the solution of the molding material and creating bubbles by stirring; directly blowing gas into the solution of the molding material to aerate the molding material; A method of dissolving either a gas-generating substance such as sodium bicarbonate or an acid in a solution, and adding the other gas-generating substance or acid to this solution to generate gas and aerate it. There are many methods, but the method is not particularly important as long as it can be aerated.

Furthermore, a modified material that simulates the degeneration of an organ may be added to the molded product. The denatured material is a material that imitates the material that becomes scorched due to protein denaturation when an electric scalpel comes into contact with an organ, for example. Examples of the modified material include sugars, proteins, polyphenols, amino acids, and celluloses. The modified material may be made into a film and applied to the organ model, or may be kneaded into the organ model. The thickness of the film-like modified material is preferably 10 μm or more and 5 mm or less. By adding denatured materials to organ models, for example, when practicing surgery using an electric scalpel, it is possible to create a charred state when the electric scalpel comes into contact with the epidermis, near blood vessels, deep inside organs, etc. It becomes possible to express. Furthermore, the texture of the denatured material that is conveyed to the surgeon through a scalpel, etc., when the denatured material is made of sugars, proteins, polyphenols, amino acids, cellulose, etc., resembles the "charred" texture of real epidermis, blood vessels, organs, etc. It can be made into something. By distributing the modified material in the form of a film onto the organ model, there is no need to incorporate the modified material into the organ model during production, which facilitates production. Furthermore, by using a modified material in the form of a film, it is efficient because the modified material can be applied only to the necessary locations. In addition, the film-like modified material can be added to an organ model etc. by simply applying it, so it can be adjusted at the time of use. Furthermore, the film-like modified material allows for simple imitation tests to be performed only on areas where it is desired to practice electrocautery, such as around blood vessels and the epidermis.
Here, a method of incorporating a modified material into an organ model will be explained. For example, when the molding material is a thermoreversible gel, the modified material is added and dissolved before or after dissolving the molding material in water. By pouring a solution containing the molding material containing the modified material into a mold and cooling it to gel, the modified material can be incorporated into the organ model having a thermoreversible gel.
For example, if the molding material is a thermosetting gel, the modified material may be added after dissolving or dispersing the molding material in water or lukewarm water, or directly to the molding material in a solution state such as egg white. A solution containing a molding material is poured into a mold and heated to gel. This allows the modified material to be incorporated into the organ model having the thermosetting gel.
For example, when the molding material is a cation-reactive gel, the modified material is added and dissolved before or after dissolving the molding material in water. Slightly soluble calcium or the like is added to the solution containing the molding material containing this modified material, poured into a mold, cooled and gelled. This allows the modified material to be incorporated into the organ model having the cation-reactive gel.
Next, a method for forming a modified material into a film will be described. First, when producing a film using a film base material such as agar, konjac, carrageenan, gelatin, cellulose derivative, pullulan, etc., a modified material is added to the film base material while the film base material is in a solution state. There is a way to make it into a film.
Next, a film containing the modified material can be produced by immersing the formed film in the modified material in a solution state, or by spraying the modified material in a solution state to impregnate the film and drying.
These films are applied directly to an organ model or after being swollen in water or the like. This allows for close contact with the organ model.
Alternatively, a film may be attached to a mold in advance using an adhesive or the like, and a solution of the molding material may be poured into the mold to gel.

After the molding material has sufficiently penetrated into the transfer recesses 2a and 2b, the temperature of the pair of molds 1a and 1b is cooled to 20°C. This completes the molding. The human heart organ model 8 is translucent. The set of molds 1a, 1b can be used many times to mold the molding material. Note that since the entire organ model 8 is molded using the molds 1a and 1b, it becomes a molded article 19. In the above manner, the object having the gel according to the first embodiment is manufactured.

FIG. 5 is a schematic diagram in which a human heart organ model 8, which is a molded product, is visible, assuming that a pair of molds 1a and 1b are transparent.

(Main effects obtained by the first embodiment)
Since the first embodiment uses a mold obtained with a 3D printer, it is possible to easily manufacture the human heart organ model 8 that is the molded product. Further, since the molds 1a and 1b can be used for molding the molding material many times, it is possible to reduce the manufacturing cost of the organ model 8.

The organ model 8 obtained according to the first embodiment can have a tactile sensation that is similar to the real thing. Further, this organ model 8 can have a feel similar to the real thing when cut with a scalpel or Pean. Therefore, this organ model 8 is suitable for use in pre-surgery practice or in training for doctors. Furthermore, the organ model 8 is useful because it allows the user to practice suturing on the organ model 8 when practicing suturing during surgery. The organ model 8 is also useful when simulating the route to a tumor or the like because the organ model 8 can be used for simulation. Further, the organ model 8 is useful because it can be injected into the organ model 8 when practicing injections such as during surgery. Further, the organ model 8 and the like are useful because the organ model 8 can be used for evaluation and safety testing of medical devices, or for verification. Further, the organ model 8 is useful because the medical robot can be moved relative to the organ model 8 during training for learning how to operate the medical robot. In addition, organ model 8 is useful because tests can be performed on organ model 8 when practicing PTC (percutaneous transhepatic cholangiography) or PTCD (percutaneous transhepatic bile duct drainage). be. Furthermore, the organ model 8 can also be used to simulate an ultrasonic medical device. Furthermore, by making a tube-like object from the esophagus to the stomach or from the anus to the intestines using a gel (molded object) similar to organ model 8, it is possible to practice endoscopy. It is said that the more times a person cuts organs, etc., the better the doctor becomes, so if one can gain experience using this organ model 8, it is thought that this organ model 8 will make a great contribution to medicine. Furthermore, since the organ model 8 is mainly composed of agar, which is a type of food, it is highly environmentally friendly even if it becomes waste. Additionally, in the past, it has been done to kill living animals and remove their organs to obtain human organ models (substitutes), but this embodiment There is no need for unnecessary killing. In addition, the softness of the molded product can be adjusted by increasing or decreasing the amount of water in the molding material, such as agar, and the texture of the molded product can be changed by mixing fibrous materials, etc. It is possible to obtain molds with different textures.

In the first embodiment, a set of molds 1a and 1b of an organ model 8 are manufactured using a 3D printer. 3D printers have the characteristic of being able to reflect three-dimensional CAD data into printed matter, that is, the shape of objects, with surprising fidelity. 3D printers are said to be able to express unevenness as fine as 16 μm. Therefore, it is possible to manufacture a mold in which fine irregularities such as blood vessels are faithfully transferred to the transfer recesses 2a and 2b. The effect of faithfully transferring these fine irregularities cannot be obtained when conventional molds are used, and can only be obtained when molds 1a and 1b are manufactured using a 3D printer. Moreover, the cost and time required to manufacture a set of molds 1a and 1b using a 3D printer can be reduced to about 1/6 of that of conventional molds.

For example, in the schematic cross-sectional view of the transfer recess 2a of the mold 1a as shown in FIG. The molded article 19 can be released from the mold. The reason for this is that the molding material is agar, and the molded product 19, which can be said to be liquid, has a very low viscosity. This is because they can crawl under the surface.

(Contents of the method for manufacturing an object having gel according to the second embodiment)
Hereinafter, a method for manufacturing an object having gel according to a second embodiment will be described with reference to the drawings. FIG. 7 is an external view of a blood vessel 11 (an imitation of a biological tissue different from a molded article, or a surgical material) according to the second embodiment. FIG. 8 is an external view of a liver organ model. FIG. 9 is a photograph substituted for a drawing of a set of liver molds according to the second embodiment. FIG. 10 is a photograph substituted for a drawing in which an organ model is fitted into a transfer recess of a set of liver molds according to the second embodiment. FIG. 11 is a photograph substituted for a drawing of an organ model according to the second embodiment. Note that unless otherwise specified, the method of manufacturing the mold, the material of the gel, that is, the molded product 21, and the molding method according to the second embodiment are the same as those of the first embodiment, and detailed explanation thereof will be omitted. .

The object having the gel according to the second embodiment is a human liver organ model 22 having a molded object 21 and a blood vessel 11. In the organ model 22, a part of the blood vessel 11 is embedded in the molded article 21. This blood vessel 11 is made of resin material and is modeled using a 3D printer. Further, the blood vessels 11 are colored blue and red. The blood vessel 11 becomes a part that is harder than the molded article 21. Since the molded object 21 is a soft object, that is, a gel, manufactured using agar and water as molding materials, the organ model 22 is an object having the gel according to the second embodiment. Note that the blood vessel 11 has an artery portion that becomes a thick trunk 11a and a thin blood vessel portion 11b.
In this way, it is preferable that the living tissue such as the blood vessel 11 and the molded article 21 have different colors so that they can be visually distinguished, and it is more preferable that the living tissue such as the blood vessel 11 has a color that imitates the living tissue of a human body or an animal. Moreover, the molded article 21 is a body tissue imitation (liver) different from one body tissue imitation (blood vessel 11).

During molding, blood vessel 11 is partially embedded in molded product 21 in molds 20a and 20b similar to molds 1a and 1b. We will explain how to bury it. This pair of molds 20a, 20b is made of resin material. One of the molds 20a has a transfer recess 23a into which the shape of about half of the human liver has been transferred, and the other mold 20b has the shape of the remaining half of the human liver described above. There is a transfer recess 23b whose shape has been transferred. The transfer recesses 23a and 23b are recessed relative to the reference surfaces 24a and 24b that are in close contact with each other when the pair of molds 20a and 20b are closed.

One mold 20a has recesses 25a, 25b, and 25c in the area where the shape of the "object" is not transferred, and the other mold 20b has recesses 25a, 25b, and 25c in the area where the shape of the "object" is not transferred. There are protrusions 26a, 26b, and 26c that can be fitted into the recesses 25a, 25b, and 25c. By fitting the recess 25a and the projection 26a, the recess 25b and the projection 26b, and the recess 25c and the projection 26c, the transfer recess 23a and the transfer recess 23b are aligned. When the positions are aligned in this way and the pair of molds 20a and 20b are in a closed state and the reference surfaces 24a and 24b are in close contact with each other, the two transfer recesses 23a and 23b will be formed. The created space can be made to have the exact shape of a human liver.

Note that when the pair of molds 20a, 20b is open, grooves 27a, 27b for supplying molding material from the outside to the transfer recesses 23a, 23b are provided in each of the molds 20a, 20b. When the pair of molds 20a, 20b is closed, the two grooves 27a, 27b serve as a path, forming a molding material supply path 28 that supplies molding material from the outside to both the transfer recesses 23a, 23b.

The transfer recesses 23a and 23b include transfer recesses 23c and 23d in which the thick trunk 11a of the blood vessel 11 is placed, and the blood vessel 11 is placed in that space. Then, when the pair of molds 20a, 20b are closed, the blood vessel 11 does not move, and the thin blood vessel portion 11b is placed in the space formed by the transfer recesses 23a, 23b. Thereafter, the remaining gaps between the transfer recesses 23a and 23b are filled with a molding material made of agar and water from the molding material supply path 28, and the molded article 21 is molded in the same manner as in the first embodiment. Through the above steps, the organ model 22 in which the blood vessel 11 is embedded in the molded article 21 can be manufactured. As shown in FIG. 11, what is embedded in the molded product 21 is mainly the thin blood vessel portion 11b, and most of the thick trunk 11a is not embedded in the molded product 21.

(Main effects obtained by the second embodiment)
In the second embodiment, it was possible to obtain a human liver organ model 18 in which the tactile sensation of the blood vessel 11 was different. The organ model 22 is an organ model 22 in which the blood vessels 11 are made hard and the molded object 21 is made soft with agar and water, so that the blood vessels 11 are prominent.

Further, the organ model 18 allows the user to practice surgery while being aware of the position of the blood vessel 11. Therefore, it is possible to provide an organ model 18 for surgical practice that is more realistic. Furthermore, the blood vessel 11 can be used once for the organ model 22 and then reused many times after cutting the molded object 21 with a scalpel or the like, resulting in a greater cost reduction for the organ model 22.

Further, the effects obtained by the second embodiment include the effects of the first embodiment.

(Contents of the method for producing an object having gel according to the third embodiment)
Hereinafter, a method for manufacturing an object having gel according to a third embodiment will be described with reference to the drawings. FIG. 12 is a schematic cross-sectional view showing a state in which a water-soluble resin is placed in a molded article 32 according to the third embodiment. FIG. 13 is a schematic cross-sectional view showing a state in which a cavity is formed in the molded article 32 by melting the water-soluble resin from the state shown in FIG. Note that unless otherwise specified, the method of manufacturing the mold, the material of the gel, that is, the molded article 32, and the molding method according to the third embodiment are the same as those of the first embodiment, and detailed explanation thereof will be omitted. .

In the third embodiment, the molded article 32 is an organ model 33 of a human heart. The cavity 12 is open in the organ model 33. During molding similar to the organ model 8 according to the first embodiment, this cavity 12 contains a water-soluble resin 13 made of a substance soluble in water of 80° C. or lower, here polyvinyl alcohol, in the molding material. After the molding is completed, the water-soluble resin 13 is made by contacting with water at room temperature of about 25°C. Since the water-soluble resin 13 is soluble in water at 80° C. or lower, it is charged into the organ model 8b and forms the cavity 12 after being dissolved.

(Main effects obtained by the third embodiment)
The cavity 12 can be created in the organ model 33 according to the third embodiment. Since the human heart has cavities such as a right atrium, a left atrium, a right ventricle, and a left ventricle, the third embodiment makes it possible to realistically create the organ model 33. Furthermore, in the case of "objects" other than organ models, more complex shapes can be easily created according to the third embodiment.

The water-soluble resin 13 can be discharged from the entrance 14 once melted, even if there is a part where the entrance 14 is narrower than the back side 15 in the cross-sectional view of the organ model 33. Therefore, a complex-shaped cavity 12 can be formed in the organ model 33.

Further, the effects obtained by the third embodiment include the effects of the first embodiment.

(experiment)
Experiments 1 to 5 will be described below regarding examples of materials having the above-mentioned gelling properties.
Experiment 1
Molding experiment of thermoreversible molding material A molded article was produced using the formulation shown in Table 1 (the amount of water was finally adjusted so that the amount produced was 1000 g).
Samples 1 to 6 were prepared by adding a molding material (a part of the molding material) to water, dispersing it, heating and dissolving it, and then adding and mixing the pigment and glycerin to produce the molding material. This was filled into molds 1a and 1b produced using a 3D printer and cooled to 10°C to produce a molded product. Further, similarly to the second embodiment, an object having a gel was produced by filling the molding material together with the blood vessel 11 into molds 20a and 20b produced by a 3D printer and cooling them to 10°C.
Agar: Ina Agar Yamato (Product Name) Manufactured by Ina Foods Co., Ltd. Carrageenan: Inagel E-150 (Product Name) Manufactured by Ina Foods Co., Ltd. Locust Bean Gum: Inagel L-85 (Product Name) Manufactured by Ina Foods Co., Ltd. Gluco Mannan: Inagel Mannan 100 (Product name) Manufactured by Ina Foods Co., Ltd. Xanthan gum: Inagel V-10 (Product name) Made by Ina Foods Co., Ltd. Tamarind gum: Inagel V-250C (Product name) Made by Ina Foods Co., Ltd. Native Gellan gum: LT-100 (product name) manufactured by CP Kelco Psyllium seed gum: Inagel A-450 (product name) manufactured by Ina Foods Co., Ltd. Experimental results of experiment 1: Molded products 19 and 21 of samples 1 to 7 are the molded products. It was possible to maintain the shape of an object without applying force (including gravity), faithfully reproduce the fine irregularities of a heart or liver, and create something that had a tactile sensation exactly like that of a heart or liver.

Experiment 2
Molding Experiment of Thermosetting Molding Material A molded article was produced using the formulation shown in Table 2 (the amount of water was finally adjusted so that the amount produced was 1000 g).
For sample 8, curdlan, starch, glycerin, and pigment were added to water, dispersed, and then filled into molds 1a and 1b prepared using a 3D printer. A molded product was produced by heating this to 95°C.
In addition, curdlan, starch, glycerin, and pigment were added to water, dispersed, and then filled together with blood vessels 11 into molds 20a and 20b produced using a 3D printer, as in the second embodiment. By heating this to 95° C., a gel-containing object was produced.
Curdlan: Manufactured by Takeda Kirin Foods Co., Ltd. Starch: Matsunorin M (trade name) Manufactured by Matsutani Chemical Industry Co., Ltd. Experimental results of Experiment 2: Molded articles 19 and 21 of sample 8 were ), it was possible to faithfully reproduce the fine irregularities of the heart or liver, and it was possible to create a texture that was exactly like that of the heart or liver.

Experiment 3
Molding experiment of cation-reactive molding material A molded article was produced using the formulation shown in Table 3 (the amount of water was finally adjusted so that the produced amount was 1000 g).
Sample 9 was prepared by dissolving sodium alginate, monocalcium phosphate, and glucono-delta-lactone in water, filling it into a mold, and leaving it for 24 hours to produce a molded product.
Sample 10 was prepared by dissolving glycerin, polyvinyl alcohol, and borax in water and filling it into a mold. The mixture was heated to 60°C and reacted with cations to produce a molded product.
Sample 11 was prepared by dispersing gellan gum in water and dissolving it by heating. To this was added a 10% aqueous solution of calcium lactate. The mixture was filled into a mold while hot and cooled to 20°C to react with calcium to produce a molded product.

These molds are molds 1a and 1b and molds 20a and 20b produced using a 3D printer. When using molds 20a and 20b, samples 9 to 11 were molded together with blood vessel 11 in the same manner as in the second embodiment.
Sodium alginate: Inagel GS-130 (product name) manufactured by Ina Foods Co., Ltd. Polyvinyl alcohol: Hibis Wako (product name) manufactured by Wako Pure Chemical Industries Ltd. Gellan gum: Kelcogel (product name) manufactured by CP Kelco Agar: Ina Agar Yamato (product name) Ina Manufactured by Shokuhin Kogyo Co., Ltd. Carrageenan: Inagel E-150 (product name) Manufactured by Ina Food Industry Co., Ltd. Locust bean gum: Inagel L-85 (product name) Manufactured by Ina Food Industry Co., Ltd. Glucomannan: Inagelmannan 100 (product name) Manufactured by Ina Food Industry Co., Ltd. Xanthan gum: Inagel V-10 (product name) Manufactured by Ina Food Industry Co., Ltd. Tamarind gum: Inagel V-250C (product name) Manufactured by Ina Food Industry Co., Ltd.

Experimental results of Experiment 3: Molded articles 19, 21, and 32 of Samples 9 to 11 can maintain their shapes without applying force (including gravity), and faithfully reproduce the fine irregularities of the heart or liver. It was possible to make it feel exactly like those.

Note that the solvent used in Experiments 1, 2, and 3 was all water, but depending on the type of solute, part or all of the solvent may be an organic solvent such as alcohol.
Molding materials other than Samples 1 to 11 above that have thermoreversible, thermosetting, or cationic reactivity gelling properties, such as agar, carrageenan, farcellan, gelatin, xanthan gum, cassia gum, guar gum, tara gum, A molding material containing one or more selected from locust bean gum, fenugreek gum, glucomannan, tamarind gum, gellan gum, native gellan gum, alginate, pectin, curdlan, starch, egg white, processed egg white, and polyvinyl alcohol (mixing ratio (including those with different values), experimental results roughly equivalent to those of Samples 1 to 11 can be obtained.

Experiment 4
A film was formed on the object having the gel prepared in Sample 4.
As a result of the experiment, good films were formed in all films 1 to 10.

Experiment 5
Sample 1, Sample 8, and Sample 9 were aerated.
Sample 1 was prepared by adding and dissolving 0.5% of baking soda in a solution at 50°C before filling it into a mold, then adding 5% of a 10% citric acid solution to foam and aerate it, and filling this into the mold. It was rapidly cooled and molded.
For sample 8, a fine air nozzle was inserted into the solution at 40° C. before it was filled into the mold, and air was introduced into the solution to aerate the solution. This was filled into a mold, heated to 95°C, and molded.
Sample 9 was prepared by adding 2% powdered egg white for confectionery to a 20°C solution before filling it into a mold, aerating it with a high-speed stirrer, immediately filling it into the mold, and leaving it for 24 hours to form a molded product. .
The objects containing the aerated gel in Sample 1, Sample 8, and Sample 9 had a lighter specific gravity and a softer feel than those that did not contain air.
The aerated gels of Sample 1, Sample 8, and Sample 9 are particularly suitable for creating a human lung organ model because of their texture.

(Contents of the method for producing an object having gel according to the fourth embodiment)
Hereinafter, a method for manufacturing an object having gel according to a fourth embodiment will be described with reference to the drawings. Incidentally, unless otherwise specified, the method of manufacturing the mold, the material of the gel, that is, the molded product, and the molding method according to the fourth embodiment are the same as those of the second embodiment, and detailed explanation thereof will be omitted. 16 and 17 are perspective views of molds 50a and 50b according to the fourth embodiment, which have the same shape as molds 20a and 20b shown in FIGS. 9 and 10. Therefore, configurations that are substantially the same as those of the molds 20a and 20b are given the same reference numerals, and explanations thereof will be omitted.

The molds 50a and 50b are made by arranging a plurality of resin materials having different physical properties and colors at predetermined positions. Physical properties of the resin material include, for example, hardness, surface roughness, heat resistance, and thermal conductivity. The printing conditions of the 3D printer are adjusted so that the resin material has specific physical properties and is arranged in a specific manner, and the molds 50a and 50b are formed. At this time, data for arranging the physical properties and colors of the resin material, etc. are added to the three-dimensional CAD data. The 3D printer used has a function that allows a plurality of resin materials with different physical properties and colors to be placed at predetermined positions.

The resin materials of the molds 50a, 50b and their arrangement will be described with reference to FIGS. 16, 17, and 18, which is a sectional view taken along the line AA in FIG. 16. The reference surfaces 24a, 24b, the outer wall 54, and other parts of the outer wall 54 of the molds 50a, 50b other than the transfer portions 23a, 23b and the edges 233a, 233b (described later) have a heat resistance other than that of the molds 50a, 50b. Use a resin material that is higher than that of the parts. This is because the temperature of the reference surfaces 24a, 24b, outer wall 54, etc. increases the most during molding.

As shown in FIG. 18, a resin material having higher toughness (elasticity) than other parts is used for the cross-sectional inner layer 53 of the mold 50a. This is to give flexibility to almost the entire molding die 50a, 50b. If the molds 50a and 50b are made of the same resin material as the outer wall 54, there is a risk that the mold 50a will crack. Note that not only the mold 50a but also the cross section of the mold 50b has a flexible cross-sectional inner layer 53 as shown in FIG. 18.

Of the transfer parts 23a and 23b, the blood vessels other than the blood vessel 52 (not shown in the figure, but the blood vessel according to the fourth embodiment is referred to as the blood vessel 52 to distinguish it from the blood vessel 11. The same applies hereinafter) A resin material having lower thermal conductivity than other parts is used for the transfer parts 230a and 230b that transfer the shape of the liver. In this case, a material with a thermal conductivity of 0.15 (W/m·K) is used, but values other than this may be used. This is because the transfer portions 230a and 230b have very complicated shapes, so the gel flowing therein is made to have good fluidity, harden as slowly as possible, and make it difficult to cause molding defects. Thus, slowing down the curing rate of a gel generally increases the water content of the gel and making it softer than increasing the curing rate.

Of the transfer parts 23a and 23b, the transfer parts 232a and 232b, which transfer the thick trunk 52a of the liver blood vessel 52, are made of a resin material with higher thermal conductivity than other parts. This is because, like the blood vessel 11, the blood vessel 52 is made of a resin material and is modeled using a 3D printer, so it is not molded by the molds 50a and 50b, and it is not molded by the molding molds 50a and 50b. This is because there is no need to lower the temperature. Rather, this is because the blood vessel 52 needs to be prevented from being deformed by being heated by the molds 50a and 50b as much as possible.

The edge portion 233a, which is a region surrounding the entire periphery of the transfer portions 23a and 23b by about 5 mm, is made of an elastic resin material that feels like rubber. The Shore hardness of the resin material used here is 60°. The edges 233a and 233b are for maintaining airtightness so that the gel does not flow out between the molds 50a and 50b when the gel is placed in the mold with the molds 50a and 50b closed. . Therefore, although not clearly shown in FIGS. 16 and 17, as shown in FIG. 18, the edges 233a and 233b slightly protrude from the reference surfaces 24a and 24b. This protruding portion maintains the above-mentioned airtightness when the reference surfaces 24a, 24b are aligned and the molds 50a, 50b are in a closed state. The broken lines in FIGS. 16 and 17 indicate the boundaries between the edges 233a and 233b and the reference surfaces 24a and 24b.

FIG. 19 shows a flowchart of a method for manufacturing molds 50a and 50b according to the fourth embodiment. The method for manufacturing the molds 50a and 50b goes through the same steps as steps S1 to S4 in FIG. 1 showing the molds 1a and 1b in the first embodiment (S11). Thereafter, a plurality of sections of the molds 50a and 50b each partitioned into a three-dimensional shape are set in the three-dimensional CAD data obtained in steps S1 to S4 (S12). Next, the physical properties and color of the resin material to be supplied to each section are set in the three-dimensional CAD data (S13).

Then, based on the three-dimensional CAD data of the pair of molds 50a, 50b, the pair of molds 50a, 50b are respectively modeled using the aforementioned 3D printer (S14). At this time, the 3D printer mixes multiple types of resin materials and jets them to form a resin material with specific physical properties to form each section. The molds 50a, 50b are a combination of a pair of molds 50a, 50b. One of the molds 50a has a transfer recess 23a into which the shape of about half of the human liver is transferred, and the other mold 50b has the shape of the remaining half of the human liver described above. There is a transfer recess 23b whose shape has been transferred. The transfer recesses 23a and 23b are recessed relative to the reference surfaces 24a and 24b that are in close contact with each other when the pair of molds 50a and 50b are closed.

The blood vessel 52 is manufactured from a plurality of resin materials having different physical properties or colors. Further, the blood vessel 52 has the same external shape as the blood vessel 11. For example, the blood vessel 52 has an artery portion that is a thick trunk 52a and a thin blood vessel portion 52b. Here, the hardness and the like are changed depending on the location of the blood vessel 52. This blood vessel 52 is also manufactured using a 3D printer that has the ability to place a plurality of resin materials with different physical properties and colors at predetermined positions. The manufacturing method is similar to that of the mold 50a. FIG. 20 shows the manufacturing flow diagram. A plurality of sections partitioned into three-dimensional shapes are set in the three-dimensional CAD data of the blood vessel 52 (S22). Next, the physical properties and color of the resin material to be supplied to each section are set in the three-dimensional CAD data (S23). Then, the blood vessel 52 is modeled based on the three-dimensional CAD data of the blood vessel 52 (S24).

In the fourth embodiment, the blood vessel 11 used in the second embodiment may be used instead of the blood vessel 52 in the human liver organ model molded with the molds 50a and 50b. Further, other blood vessels may be used instead of the blood vessels 52 and 11.

FIG. 21 is a diagram showing how the blood vessel 52 is placed in the mold 50a before the gel is put into the mold 50a. The artery 52a is fitted into the transfer portion 232a with almost no gap. Therefore, in the blood vessel 52, the artery 52a was fixed by the transfer portion 232a, and no wobbling or the like occurred. Furthermore, the artery 52a is also fitted into the transfer portion 232b of the mold 50b with almost no gaps. Therefore, the thin blood vessel portion 52b can float in the transfer parts 230a, 230b without coming into contact with the transfer parts 230a, 230b. Therefore, it is possible to obtain a molded article in which the thin blood vessel portion 52b is completely buried in the gel. This also applies to the second embodiment. In addition, in FIG. 21, the description of the edges 233a and 233b is omitted.

(Main effects obtained by the fourth embodiment)
According to the fourth embodiment, the hardness, surface roughness, heat resistance, elasticity, thermal conductivity, etc. of each section of the molds 50a and 50b can be changed. For example, if the thermal conductivity of each section of the molds 50a, 50b can be varied, the rate of gel curing can be partially adjusted. Moreover, if the hardness of each section of the molds 50a, 50b can be changed, the sturdiness or strength of the molds 50a, 50b can be partially adjusted. Furthermore, if the surface roughness of the molds 50a, 50b can be changed, the design of the molds 50a, 50b can be partially adjusted. Moreover, if the heat resistance of each section of the molds 50a, 50b can be changed, the heat resistance of the molds 50a, 50b can be partially adjusted. Moreover, if the elasticity of each section of the molds 50a, 50b can be changed, the molds 50a, 50b can be sealed by the edges 233a, 233b, or the flexibility of almost the entire molds 50a, 50b can be made flexible by the cross-sectional inner layer 53. It is possible to give gender.

A 3D printer can be equipped with up to six ink cartridges that store and supply resin material, and can simultaneously eject resin material from each cartridge. Therefore, the molds 50a, 50b can be manufactured by disposing the resin material necessary for manufacturing the molds 50a, 50b as an integrally molded object (one mass) that does not require a connecting member in a single printing operation.

As in the fourth embodiment, by changing the hardness of each section of the molds 50a and 50b, it is possible to make a molded part of a model of an organ such as a human liver more realistically. The human liver is not an artificial object, so strictly speaking, the hardness etc. of each part should be different, but if you make a molded object from gel, all parts of the human liver will inevitably have the same hardness etc. Put it away. The fourth embodiment makes it possible to realize such a delicate texture of the human liver using an organ model.

When the resin material of the edges 233a and 233b is made based on a metal mold instead of the molds 50a and 50b, it is usual to form the resin material by pasting rubber or the like to a predetermined location of the mold. Usually, the rubber etc. attached to this mold peel off very easily. However, since the mold 50a is an integrally molded product, the edges 233a and 233b are extremely difficult to peel off.

(other forms)
Although the method for producing an object having gel according to the first, second, third or fourth embodiment described above is an example of a preferred embodiment of the present invention, the present invention is not limited thereto. Various modifications can be made without changing the gist of the invention.

In the first, second, third, or fourth embodiments, the "object" is a human heart or liver organ model 8, 22, or 33. However, other organ models such as a human kidney organ model may be used. It may also be used as an animal organ model. Furthermore, the "object" may be a so-called medical model such as human skin, eyeballs, or brain. In addition to surgical care, "medical care" in this medical model includes dentistry, plastic surgery, cosmetic surgery, etc. Furthermore, objects containing gel in fields completely unrelated to medical care, such as dolls, may also be used. For example, the "object" may be an earthworm used as bait for fishing. If the worms are made of agar, etc., it will not have a negative impact on the natural environment even if they are discarded.

In the first, second, third, or fourth embodiments, the molding material for the molded products 19, 21, and 32 is a sol state in which water and agar are mixed and dissolved by heating. Materials having different gel strength and viscoelasticity may be used, such as those having gelation properties such as thermosetting or cationic reactivity, or those containing resin. The reason for this is that it is possible to achieve a tactile sensation similar to the softness of an organ or the like. The molding material used was a mixture of water and agar, and the mixing ratio was 20 g of powdered agar to 1000 g of water. However, the concentrations of the mixed and dissolved solutions can be varied as appropriate. For example, if you want to make the molded product soft, you increase the water content, and if you want to make the molded product hard, you decrease the water content. Furthermore, it goes without saying that the gels and the like used in Experiments 1 to 5 can be used in the first, second, third, or fourth embodiments.

The molding material for the molded articles 19, 21, and 32 produced using a 3D printer is preferably a material having gelling properties such as thermoreversible, thermosetting, or cationic reactivity, such as agar, Carrageenan, farcellan, gelatin, xanthan gum, cassia gum, guar gum, tara gum, locust bean gum, fenugreek gum, glucomannan, tamarind gum, gellan gum, native gellan gum, alginate, pectin, curdlan, starch, egg white, processed egg white, polyvinyl alcohol , psyllium seed gum. The reason for this is that it is possible to achieve a tactile sensation similar to the softness of an organ or the like. In addition, for materials with gelling properties such as thermoreversible, thermosetting, or cationic reactivity, the molding material is usually gelled by cooling, heating, or cationic reaction, but it is also possible to gel the molding material by other methods. You can also make it into

In the first, second, third, or fourth embodiment, the organ models 8, 22, and 33 are translucent. However, the colors of the organ models 8, 22, and 33 can be any color. For example, it can be colored exactly like that organ. Moreover, the blood vessel 11, which is a hard part, may have a part that is a different color from the molded articles 19, 21, and 32. Furthermore, for example, the organ models 8, 22, and 33 can be colored by mixing food coloring with the molding material. Moreover, the surfaces of the organ models 8, 22, and 33 can also be colored after molding.

In the first, second, third, or fourth embodiment, the three-dimensional CAD data of the human heart or liver is obtained by scanning the human heart with a three-dimensional scanner. However, the three-dimensional CAD data of the "object" does not necessarily need to be obtained using a three-dimensional scanner, and may be obtained by operating a three-dimensional CAD, for example.

In the second embodiment, the highlighted portion of the human liver organ model 22 is the blood vessel 11 (which imitates a living tissue different from the molded article 21). However, in the organ model 8a, the portion to be highlighted is not limited to the blood vessel 11, but may be a portion of the tumor 11c, as shown in FIG. 8, for example. The tumor 11c part is the hardest part of the human liver, so a human liver organ model in which the tumor 11c part is made hard and the other parts are made soft becomes a more realistic organ model. Such organ models can also be used to practice tumor removal surgery. Furthermore, a part or all of a body tissue imitating an organ or the like may be embedded in the gel-containing object. This living tissue includes one or more selected from tumors, calculus, teeth, and dental calculus. Here, the biological tissue may be modeled using a 3D printer or may be formed using a mold.

The living tissue is one that imitates part or all of the human body or animal body; for example, in the case of humans, the cerebrum, cerebellum, brain stem, heart, lungs, bronchi, pharynx, tongue, ears, eyes, stomach, Modeling one or more of the following: small intestine, large intestine, gallbladder, liver, kidney, pancreas, esophagus, duodenum, adrenal gland, testis, bladder, uterus, breast, muscle, artery, vein, lymph, spinal cord, bone, nail, and skin. You may do so. Furthermore, not only normal cells but also abnormal cells such as tumors may be molded and modeled.

Furthermore, "imitation of living tissue" includes those whose shape or texture is deliberately different from that of actual living tissue. For example, if there is a blood vessel 52 and a vein in the liver that was not explained in the fourth embodiment, the hardness of the artery 52a and vein will be determined when a doctor applies a medical treatment instrument such as a hypodermic needle. , the touch may be different depending on whether it is applied to the artery 52a or the vein. This ``imitation of living tissue'' that provides a different feel when struck by a medical treatment instrument is extremely useful for trainee doctors when practicing surgery. The 3D printer used in the fourth embodiment is suitable for modeling such "imitations of biological tissue" having different hardness and the like.

The molded article 21 other than the living tissue may be a material imitating a living tissue or a surgical material such as an implant (for example, a metal plate or screw such as a titanium plate or a titanium screw, an artificial valve, an artificial (artificial objects intentionally left in the body, such as bone, calcium or calcium compounds, intravenous needles, plastic tubing, etc.) In addition, surgical materials include artificial objects (gauze, bullets, hypodermic needles, etc.) that may remain in the body unintentionally and are removed during excision surgery.

The blood vessels 11 and 52 according to the second embodiment or the fourth embodiment are made of resin material and modeled using a 3D printer. However, the blood vessels 11 and 52 may be made of a material other than a resin material, such as glass, or may be made by a method other than a 3D printer, such as injection molding, compression molding, extrusion molding, blow molding, press molding, slush molding, etc. It may also be obtained by rotation molding. Here, an object imitating a living tissue different from the molded object such as the blood vessel 11, which is molded using a mold such as injection molding, will be referred to as a "second molded object". The "object" has a part of a modeled object or a second molded object, such as blood vessels 11 and 52, and a part or all of the modeled object or the part of the second molded object is placed in a mold during molding. It may be arranged, molded together with the molded products 19, 21, 32, and embedded in the molded products 19, 21, 32. Here, the "shaped object or the second molded object" may have the same softness as the molded object 21, or may be softer than the molded object 21. Among the "modeled object or second molded object", the modeled object is, for example, one that has been modeled with a three-dimensional printer, and the second molded object is, for example, one that has been molded with a mold. In addition, the biological tissues such as the blood vessels 11 and 52 can be made of hollow rubber material as soft as a marshmallow or an earlobe using a 3D printer, so it is possible to create something that feels just like real blood vessels. In addition, by putting soft gel like molded objects 19, 21, and 32 into the hollow of such a molded object imitating a hollow rubber foot, pus (made with gel) can be removed from the foot. You can create something similar to what you have, and you can practice treating it.

In the third embodiment, polyvinyl alcohol is used as the water-soluble resin, but other water-soluble resins such as polyacrylamide, carboxymethyl cellulose, etc. may also be used. Moreover, alcohol or the like may be used instead of water as the solvent. For example, when alcohol is used as the solvent, polyvinyl alcohol with a low degree of saponification is used as the solute, and the same process as in the third embodiment where polyvinyl alcohol is dissolved in water to form the cavity 12 is performed. You can go.

In the third embodiment, a cavity 12 is formed in the organ model 8b. However, a passage such as a passage having an entrance and an exit may be formed in the organ model 33. FIG. 14 is a schematic cross-sectional view showing a state in which a water-soluble resin is placed in a molded article 32 according to a modification of the third embodiment. FIG. 15 is a schematic cross-sectional view showing a state in which the water-soluble resin is melted from the state shown in FIG. 14 to form passages in the molded article 42. The organ model 43 has a passage 16. The passage 16 has an inlet 17 and an outlet 18. The water-soluble resin 13 is placed in a space that is to become a passage 16. After the molding is completed, the water-soluble resin 13 is brought into contact with water at 25° C. to be dissolved, thereby forming the passage 16.

The molds 1a, 1b, 20a, 20b, 50a, and 50b may be partially or entirely made of a transparent resin material. By using a transparent resin material, it is possible to visualize how the organ models 8, 22, 33, 43 are molded. In addition, the molds 1a, 1b, 20a, 20b, 50a, and 50b can change, for example, the flow rate of the ultraviolet curable resin material and the curing speed of the material depending on the thermal conductivity during the manufacturing process. The hardness of 1b, 20a, 20b, 50a, and 50b can be changed. Furthermore, it is also possible to adjust the adhesion to the material of the molded articles 19, 21, 32, that is, the gel material.

Hard parts such as the blood vessels 11 and 52 may be shaped or molded using a method other than a 3D printer, but there are great advantages to using a 3D printer. For example, by combining an ultraviolet curing resin material used as a modeling material for a 3D printer and an inkjet 3D printer, materials with different physical properties can be modeled in one go. For example, even for a single object, the color, hardness, or surface friction coefficient can be changed depending on the part. Note that more than 500,000 colors can be set. Furthermore, it is possible to make hard parts such as the blood vessels 11 and 52 hollow.

The molds 1a, 1b, 20a, 20b, 50a, and 50b are formed by forming a photocurable resin material such as an ultraviolet curable resin material one layer at a time, and repeating the operation of curing the resin material by irradiating ultraviolet rays each time. A layer of material is formed and a three-dimensional shape is gradually printed, or shaped. However, the molds 1a, 1b, 20a, 20b, 50a, and 50b are not limited to those made of such a resin material. For example, the molds 1a, 1b, 20a, 20b, 50a, and 50b are not limited to those made of such a resin material. A metal mold can be made and used by making a mold made of the material, and then firing the resin material and sintering the metal powder.

In the fourth embodiment, the thermal conductivity, hardness, heat resistance, and elasticity of the resin material of the molds 50a and 50b were adjusted. However, in addition to this, one or more factors selected from color, surface roughness, water absorption, surface temperature, impact resistance, viscosity, and adhesion may be adjusted.

Furthermore, in the fourth embodiment, one or more factors selected from gel fluidity, curing speed, or surface roughness were adjusted depending on the site. However, in addition to this, the water content etc. may be adjusted.

In the fourth embodiment, when arranging the resin material of the molds 50a and 50b, a plurality of sections are set in which each part is partitioned into a three-dimensional shape (S12). Furthermore, a plurality of sections partitioned by the three-dimensional shape of the blood vessel 52 are set (S22). However, if there is a method other than setting a plurality of sections partitioned into three-dimensional shapes when arranging a plurality of types of resin materials on a modeled object, that method may be adopted.

In the fourth embodiment, for example, the hardness of parts of the organ model that should not be cut with a scalpel or the like and parts that can be cut can be changed. This is because the 3D printer used in the fourth embodiment has a function that allows a plurality of resin materials having different physical properties including hardness to be placed at predetermined positions. For example, if a vein must never be cut during surgery, an organ model is created in which the vein is made harder than other parts. Then, when a scalpel or the like hits a vein during a surgical operation, the sensation of "hardness" is transmitted to the surgeon through the scalpel, etc., making it a suitable organ model for surgical practice.

FIG. 22 is a modification of the fourth embodiment, and shows a blood vessel 52 of a liver organ model.If the blood vessel 52 is cut at a thin blood vessel portion 52b or the like, a blood-colored cross section 55 will appear. It was difficult to create such a mechanism for conventional organ models, which are made to be exposed, but the 3D printer according to the fourth embodiment can print multiple resin materials of different colors. Since it has the function of being able to be placed in a predetermined position, such a device can be easily made. With such a device, if the thin blood vessel portion 52b is accidentally cut with a scalpel or the like, the surgeon can be made aware of the fact. Note that such a device that exposes the blood-colored cross section 55 may be applied to the thick trunk 52a of the blood vessel 52.

1a, 1b, 20a, 20b, 50a, 50b Molding mold 8, 22, 33, 43 Organ model (object with gel)
11, 52 Blood vessels (shaped objects or molded objects, imitations of living tissues different from the molded objects, or surgical materials)
13 Water-soluble resin (substances that dissolve in water below 80°C)
19, 21, 32, 42 Molded product (gel)

Claims (8)

Using a 3D printer, a plurality of resin materials with different colors or one or more physical properties selected from thermal conductivity, surface roughness, hardness, or elasticity are placed in each part of the mold, and the molding is performed . A process of making a mold,
A step of supplying a molding material having thermoreversible, thermosetting, or cation-reactive gelling properties to the mold to obtain a molded article , or
Molding one or more molding materials having any one of thermoreversible, thermosetting, and cation-reactive gelling properties using the mold so that each part of the molded product has different physical properties, Obtaining the molded article;
A method for producing an object having a gel. 2. The method for producing an object containing gel according to claim 1, wherein the molded product is a molded product imitating a biological tissue. A molded article imitating a living tissue different from the molded article or a part or all of a surgical material is embedded in the molded article,
A method for producing an object comprising the gel according to claim 1 or 2. Part or all of the molded article imitating biological tissue or the surgical material is manufactured from a plurality of resin materials having different physical properties or colors;
A method for producing an object comprising the gel according to claim 3. A molded article imitating a biological tissue or a surgical material different from the molded article has a shaped article formed using a 3D printer and/or a second molded article formed using a mold. ,
A method for producing an object comprising the gel according to any one of claims 1 to 4. The molding material may include agar, carrageenan, farcellan, gelatin, xanthan gum, cassia gum, guar gum, tara gum, locust bean gum, fenugreek gum, glucomannan, tamarind gum, gellan gum, native gellan gum, alginate, pectin, curdlan, starch, egg white. , an egg white processed product, polyvinyl alcohol, a whey protein material, a gelatin enzyme reaction product, a tamarind gum enzyme reaction product, and a psyllium seed gum, according to any one of claims 1 to 5. Method for producing objects with gel. 7. A molded article imitating a living tissue different from the molded article, or a surgical material, and the molded article have different colors that can be visually distinguished, respectively, according to any one of claims 1 to 6. A method for producing an object having a gel. 8. The method for producing an object containing gel according to claim 1, wherein the object containing gel is an object containing gel for surgical practice or for learning the operation of a medical robot.