US20180117219A1 - 3d printing of biomedical implants - Google Patents

3d printing of biomedical implants Download PDF

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Publication number
US20180117219A1
US20180117219A1 US15/569,670 US201615569670A US2018117219A1 US 20180117219 A1 US20180117219 A1 US 20180117219A1 US 201615569670 A US201615569670 A US 201615569670A US 2018117219 A1 US2018117219 A1 US 2018117219A1
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Prior art keywords
biomaterial
ink
stent
poly
stents
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US15/569,670
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English (en)
Inventor
Jian Yang
Evan C. Baker
Henry O. T. Ware
Fan Zhou
Cheng Sun
Guillermo A. Ameer
Robert Van Lith
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Northwestern University
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Northwestern University
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Priority to US15/569,670 priority Critical patent/US20180117219A1/en
Assigned to NORTHWESTERN UNIVERSITY reassignment NORTHWESTERN UNIVERSITY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: YANG, JIAN, AMEER, GUILLERMO A., BAKER, Evan C., WARE, HENRY O.T., ZHOU, FAN, SUN, CHENG
Publication of US20180117219A1 publication Critical patent/US20180117219A1/en
Abandoned legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/04—Macromolecular materials
    • A61L31/06—Macromolecular materials obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/82—Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/14—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L31/16—Biologically active materials, e.g. therapeutic substances
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/14—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L31/18—Materials at least partially X-ray or laser opaque
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/22—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
    • B29C64/135—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
    • C09D167/06—Unsaturated polyesters having carbon-to-carbon unsaturation
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2240/00—Manufacturing or designing of prostheses classified in groups A61F2/00 - A61F2/26 or A61F2/82 or A61F9/00 or A61F11/00 or subgroups thereof
    • A61F2240/001—Designing or manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0056—Biocompatible, e.g. biopolymers or bioelastomers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0059—Degradable
    • B29K2995/006—Bio-degradable, e.g. bioabsorbable, bioresorbable or bioerodible
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/753—Medical equipment; Accessories therefor
    • B29L2031/7532—Artificial members, protheses
    • B29L2031/7534—Cardiovascular protheses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2367/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • C08J2367/06—Unsaturated polyesters

Definitions

  • biomedical devices e.g., endovascular stents
  • photo-curable biomaterial inks e.g., or methacrylated poly(diol citrate)
  • Biodegradable stents both metallic and polymeric, offer promising alternatives to conventional bare metal stents (BMSs) and drug-eluting stents (DESs) in providing temporary drug release for vessel patency, resisting late stent thrombosis due to uncovered struts, and potential reduction in the usage of antiplatelet drugs (refs. 4, 9; incorporated by reference in their entireties). Moreover, disappearance of BDS over time allows for eventual recurrence of natural vasomotion.
  • BMSs bare metal stents
  • DESs drug-eluting stents
  • biomedical devices e.g., endovascular stents
  • photo-curable biomaterial inks e.g., or methacrylated poly(diol citrate)
  • systems comprising: (a) a photo-curable biomaterial ink; and (b) a 3D printing device for: (i) dispensing a layer of the photo-curable biomaterial ink in a pattern according to encoded instructions, (ii) exposing the layer of the photo-curable biomaterial ink to light to cure the biomaterial ink and produce a solidified biomaterial layer, and (iii) repeating steps (i) and (ii), with each successive layer built upon the previous layer to produce a 3D structure of the solidified biomaterial.
  • the photo-curable biomaterial ink comprises methacrylated poly(diol citrate).
  • the poly(diol citrate) comprises a polymer of citric acid and HO—(CH 2 )—OH, wherein n is 2-20.
  • the photo-curable biomaterial ink further comprises one or more of: a solvent, a photoinitiator, a co-initiator, a free-radical quencher, and a UV-absorber.
  • the 3D printing device is configured for laser scanning stereolithography, projection stereolithography, ink-jet printing, continuous liquid interface production, or combinations thereof.
  • a biomaterial device produced using a system described herein (e.g., biomaterial ink and 3D printing device).
  • biomaterial inks comprising methacrylated poly (diol citrate), solvent or dilutant, and a photoinitiator.
  • the poly (diol citrate) is a polymer of citric acid and an aliphatic diol selected from selected from HO—(CH 2 ) n —OH, wherein n is 2-20.
  • the methacrylated poly (diol citrate) is present in the biomaterial ink at 50-99 wt % (e.g., 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 99%, or ranges therebetween).
  • the solvent or dilutant is present in the biomaterial ink at 1-49.9 wt % (e.g., 1%, 2%, 3%, 4%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 49%, 49.9%, or ranges therebetween).
  • the photoinitiator is present in the biomaterial ink at 0.1-5 wt % (e.g., 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 1%, 2%, 3%, 4%, 5%, or ranges therebetween).
  • a biomaterial ink further comprises a co-initiator, a free-radical quencher, and/or a UV-absorber.
  • a biomaterial ink further comprises a radiopacity agent (e.g., iohexyl, iopromide, ioversol, ioxaglate, iodixanol, etc.).
  • a biomaterial ink further comprises a therapeutic agent (e.g., anticoagulant (e.g., heparin, Coumadin, protamine, hirudin, etc.), antithrombotic agent (e.g., clopidogrel, heparin, hirudin, iloprost, etc.), antiplatelet agent (e.g., aspirin, dipyridamole, etc.), anti-inflammatory agent (e.g., methylprednisolone, dexamethasone, tranilast, etc.), anti-proliferative/immunosuppresive agent (e.g., trapidil, tyrphostin, rapamycin, FK-506, mycophenolic acid), cytostatic drug (e.g., paclitaxel, rapamycin, rapamycin analogs (e.g., everolimus, tacrolimus, etc.), etc.), lipid-lowering agent (e.g., anticoagul
  • a biomaterial device produced by the curing of a biomaterial ink described herein.
  • mPDC polymer is a reference to one or more mPDC polymers and equivalents thereof known to those skilled in the art, and so forth.
  • the term “comprise” and linguistic variations thereof denote the presence of recited feature(s), element(s), method step(s), etc. without the exclusion of the presence of additional feature(s), element(s), method step(s), etc.
  • the term “consisting of” and linguistic variations thereof denotes the presence of recited feature(s), element(s), method step(s), etc. and excludes any unrecited feature(s), element(s), method step(s), etc., except for ordinarily-associated impurities.
  • the phrase “consisting essentially of” denotes the recited feature(s), element(s), method step(s), etc. and any additional feature(s), element(s), method step(s), etc.
  • compositions, system, or method that do not materially affect the basic nature of the composition, system, or method.
  • Many embodiments herein are described using open “comprising” language. Such embodiments encompass multiple closed “consisting of” and/or “consisting essentially of” embodiments, which may alternatively be claimed or described using such language.
  • polymer refers to a chain of repeating structural units or “monomers”, typically of large molecular mass.
  • examples of polymers include homopolymers (single type of monomer subunits), copolymers (two types of monomer subunits), and heteropolymers (e.g., three or more types of monomer subunits).
  • linear polymer refers to a polymer in which the molecules form long chains without branches or crosslinked structures.
  • branched polymer refers to a polymer comprising a polymer backbone with one or more additional monomers, or chains or monomers, extending from polymer backbone. The degree of interconnectedness of the “branches” is insufficient to render the polymer insoluble.
  • pre-polymer refers to linear or branched polymers (e.g., not significantly crosslinked) that have the capacity to be crosslinked under appropriate conditions (e.g., to form a thermoset), but have not been subjected to the appropriate conditions.
  • crosslinked polymer refers to a polymer with a significant degree of interconnectedness between multiple polymer strands, the result of which is an insoluble polymer network (e.g., a thermoset).
  • an insoluble polymer network e.g., a thermoset
  • multiple polymer stands may be crosslinked to each other at points within their structures, not limited to the ends of the polymer chains.
  • two or more different polymers may be crosslinked.
  • composite and “composite material” refer to materials or compositions generated from the combination of two or more constituent materials (e.g., compounds, polymers, etc.).
  • the constituent materials may interact (e.g., non-covalently) at the microscopic or molecular level, but typically do not react chemically (e.g., covalently).
  • the constituent materials appear homogenous.
  • biocompatible refers to materials, compounds, or compositions means that do not cause or elicit significant adverse effects when administered to a subject.
  • adverse effects include, but are not limited to, excessive inflammation, excessive or adverse immune response, and toxicity.
  • biostable refers to compositions or materials that do not readily break-down or degrade in a physiological or similar aqueous environment.
  • biodegradeable refers herein to compositions or materials that readily decompose (e.g., depolymerize, hydrolyze, are enzymatically degraded, disassociate, etc.) in a physiological or other environment.
  • the term “subject” broadly refers to any animal, including but not limited to, human and non-human animals (e.g., dogs, cats, cows, horses, sheep, poultry, fish, crustaceans, etc.).
  • the term “patient” typically refers to a subject that is being treated for a disease or condition.
  • FIG. 1 Chemical structure and proton nuclear magnetic resonance spectrum of methacrylated poly(1,12-dodecanediol citrate) polymer (left); schematic showing the reaction due to exposure to UV (right).
  • FIG. 2 (a) UV/Vis absorption spectra of Irgacure 819, Camphorqinone and 2-hydroxy-2-methylpropiophone (Homp) in ethanol; (b) UV/Vis absorption spectra of Camphorqinone at different concentrations; (c) Dynamic viscosities of methacrylated methacrylated poly(1,12-dodecanediol citrate) (mPDC) polymer solutions with different amount of ethyl acetate; (d) Compression strength of in-situ mPDC stents of different thicknesses, the stent is 21.8 mm ⁇ 5.0 mm (length ⁇ outer diameter).
  • mPDC methacrylated methacrylated poly(1,12-dodecanediol citrate)
  • FIG. 3 (a) Sketch and gross image of typical repeating stent element and full 3D CAD Design of the stent; (b & c) Scanning electron microscopy images of a printed mPDC stent showing the 20 um layers.
  • FIG. 4 (a & c) Low and high magnification of SEM images of a mesh mPDC-HDDA stent., CAD design shown in the top right corner; (b & d) low and high magnification of SEM images of sinusoidal an mPDC-HDDA stent. CAD design shown in the top right corner.
  • FIG. 5 (a) Schematic view of 3-point bending experiment with a gap of 16 mm and compressive displacement of 3.2 mm for stent with 5 mm outer diameter; (b) compressive displacement and resilience of Nitinol (21.8 mm ⁇ 5.0 mm ⁇ 0.2 mm) and mPDC stent (21.8 mm ⁇ 5.0 mm ⁇ 0.5 mm, (length ⁇ outer diameter ⁇ thickness)); (c) Simulated maximum force-displacement curves for different thickness stents and force-thickness curve at onset of kinking in 3-point bending simulation; (d) Simulated loading and displacement field for 350 um stent in 3-point bending simulation.
  • FIG. 6 (a) Scaled Applied Force vs. Maximum Displacement profile of stents with 300 um, 350 um, 400 um and 500 um in thickness. (b) Compressive strength of Nitinol BMS (21.8 mm ⁇ 5.0 mm ⁇ 0.2 mm), HDDA and mPDC printed stents with 9.1 mm ⁇ 5.5 mm in length ⁇ outer diameter, the thickness of printed stent is 500 um; (c) Scaled Maximum Usable Applied Force vs. Stent Thickness curve; (d) Typical Displacement distribution for Parallel-Plate Compression simulation of stent with 400 um in thickness.
  • FIG. 7 Exemplary process for stent generation by the methods described herein.
  • FIG. 8 Micro-CLIP printing system schematic. UV light is projected through a thin oxygen permeable membrane. Liquid polymer material solidifies in the pattern projected and the build platform raises vertically out of the liquid material bath.
  • FIG. 9 Dimensional Differential vs Light Intensity (% of max). Beside each plot is the corresponding SEM micrograph of the closest experimentally tested value to dimensional accuracy.
  • FIG. 10 Stents Printed with various materials and how that impacts their aesthetics.
  • Stent #1 47.79% mPDC, 50% DEF, 0.01% Sudan I, 2.2% Irg 819.
  • Stent #2 97.78% HDDA, 0.02% Benzotriazol, 2.2% Irg 819
  • Stent #3 97.79% HDDA, 0.01% Sudan I, 2.2% Irg 819.
  • Stent #5 50% DEF, 47.79% mPDC, 0.01% Sudan I, 2.2% Irgacure 819.
  • Stent#6 50% mPDC, 47.79% DEF, 2.2% Irgacure 819, 0.01% Benzotriazol.
  • Stents #7-9 60% mPDC, 35.58% Ethanol, 4.4% Irgacure 651, 0.02% Benzotriazol.
  • FIG. 11 Base Design: (a) CAD Drawing of full length stent. (b) CAD drawing of unit length of stent. (c) Unit Cell Design. (d) Scanning electron micrograph of design from CLIP process.
  • FIG. 12 Arrowhead Design: (a) CAD of full stent (b) CAD of unit length of stent (c) Unit cell design (D) scanning electron micrograph of Arrowhead design after CLIP process.
  • FIG. 13 Optimization information: (a) Design variables. (b) Flexibility test conditions. (c) Contour graph of Flexibility Metric (FM).
  • FIG. 14 Flexibility Optimized Base Design: (a) CAD of full length stent (b) Unit cell of stent design.
  • FIG. 15 Radial compression of 3D-printed stents at different UV intensities: A) 50% DEF, 47.78% mPDC, 2.2% Irgacure 819 and 0.02% Sudan I, B) 50% DEF, 47.76% mPDC, 2.2% Irgacure 819 and 0.04% Sudan I, C) 50% DEF, 47.72% mPDC, 2.2% Irgacure 819 and 0.08% Sudan I, and D) Radial compressive load at 20% radial compression for all stents. Black dashed line indicates the target radial load of a control bare-metal nitinol stent. Stents were post-cured at 2 ⁇ 2.5 minutes.
  • FIG. 16 Effect of post-curing time on mechanical strength of stents. All stents were printed with biomaterial ink of following composition: 50% DEF, 47.78% mPDC, 2.2% Irgacure 819 and 0.02% Sudan I. UV intensity for printing process was 100%.
  • FIG. 17 Relation between stent dimensions and radial compressive load at 20% radial compression: A) Axial dimension, B) Laeral dimension and C) Diagonal dimension. All stents were printed from biomaterial ink of following composition: 50% DEF, 2.2% Irgacure 819, and mPDC and Sudan I adding up to 47.8% together. Shaded box indicates the target dimensions, comparable to currently developed bioresorbable stents. Stents were 3D-printed at various UV intensities, but all were post-cured at 2 ⁇ 2.5 minutes.
  • FIG. 18 Mechanical properties of Arrowhead design stents: A) Dependency on the wall thickness varying between 250-600 um, B) Dependency on the strut dimensions varying between 150-200 um. Stents were printed from biomaterial ink of following composition: 50% DEF, 2.2% Irgacure 819, 47.72% mPDC and 0.08% Sudan I. Stents were postcured at 2 ⁇ 2.5 minutes.
  • FIG. 19 Mechanical properties of biomaterial ink with added accelerator compound. Stents were printed from biomaterial ink of following composition: 50% DEF, 1% Irgacure 819, 47.92% mPDC, 0.08% SUdan I and 1% Ethyl-4-Dimethylamine Benzoate (EDAB). Stents were 3D-printed at various UV intensities, but were post-cured at 2 ⁇ 2.5 minutes.
  • EDAB Ethyl-4-Dimethylamine Benzoate
  • FIG. 20 ( a - e ). Temporal series of images showing sheathing through compression of a 6.5 mm outer diameter stent to 3.1 mm, and subsequent self-expansion upon sheath retraction of 3D-printed stent. Full expansion to original diameter reached in approximately 3 minutes.
  • ABTS 2,2′-azino-bis(3-ethylbenzothiazoline-6-sulphonic acid)
  • FIG. 22 Exemplary synthesis of methacrylated poly(diol citrate).
  • biomedical devices e.g., endovascular stents
  • photo-curable biomaterial inks e.g., or methacrylated poly(diol citrate)
  • chitosan poly(4-hydroxybutyrate) (PHB), poly( ⁇ -caprolactone) (PCL), poly(L-lactide) (PLLA) and poly(D,L-lactide) (PDLLA) and its copolymers or composites have been extensively investigated for use in resorbable devices (refs. 10-16; incorporated by reference in their entireties).
  • a polylactide stents e.g., Igaki Tamai or bioabsorbable vascular stents (BVSs)
  • VFSs bioabsorbable vascular stents
  • a polylactide stents have been shown to degrade into metabolites such as lactic acid, CO 2 and H 2 O in two years and testing indicates they are safe when used in human coronary arteries (ref. 13; incorporated by reference in its entirety).
  • the self-expandable PLLA stents require 8 min for full-expansion in an aqueous environment due to the viscoelastic behavior of polymer 37° C. (ref. 17; incorporated by reference in its entirety), which increases the risk of ischemia and myocardial infarction. Late shrinkage after degradation also remains a concern.
  • metal stents there are manufacturing challenges for strut design, processing, and fabrication.
  • Rapid prototyping techniques such as stereolithography, selective laser sintering, fused deposition modeling and others have been developed for high precision manufacturing of customized biomedical devices, greatly expanding in biomedical research and tissue engineering for a broad range of functional and structural materials such as hydrogels, polymers and ceramics (refs. 18, 19; incorporated by reference in their entireties).
  • Continuous tool path planning strategies have been optimized for open sourced and commercial fused deposition machines (FDM), making a customized tracheal stent rapidly and affordably (ref. 20; incorporated by reference in its entirety).
  • FDM fused deposition machines
  • stereolithography offered the best surface finish in the process of customized tracheobronchial stents, while selective ground curing had the best repeatability of length (ref. 21; incorporated by reference in its entirety).
  • a bioabsorbable drug-coated stent was manufactured with a 300 um strut diameter using PCL polymer and a rapid prototyping technique (ref. 22; incorporated by reference in its entirety). These stents showed to be effective in reducing neointimal hyperplasia, inflammation and thrombosis formation.
  • a 3D micro jetting free molding technique has been developed to fabricate slide or snap fastener biodegradable stents with polydioxanone (PDO) (ref. 23; incorporated by reference in its entirety).
  • PDO polydioxanone
  • P ⁇ SL projection microstereolithography
  • DMDTM digital micromirror device
  • DMDTM digital micromirror device
  • biomedical devices e.g., implants (e.g., endovascular stents), etc.
  • biomaterial inks that are suitable for 3D printing processes, digital representation of stent design using Computer-aid design (CAD) modeling, devices (e.g., stents) with optimized mechanical properties using, for example, numerical simulation, fabrication processing parameters for device prototype and scalable manufacturing biomaterial ink that is photopolymerized by ultraviolet or visible light at various wavelengths, etc.
  • CAD Computer-aid design
  • stent structures such as sinusoidal formed wire, helical wrap, and/or laser-fused struts are obtainable and customizable with patient-specific features in the CAD model and subsequently fabricated using 3D printing systems with high fidelity.
  • biomaterial ink compositions e.g., polydiolcitrate solution composition
  • initiator concentration e.g., stents
  • curing conditions the mechanical properties of printed devices (e.g., stents) are tailored to closely match with blood vessel or a bare metal stent.
  • kink-resist stents are obtained by incorporating the stent strut exhibiting near-zero or negative Poisson's ratio.
  • the use of biodegradable materials allows for the encapsulation and slow release of drugs or other agents from the bulk of the stent rather than a coating that is applied to the stent struts.
  • complex 3D microstructures are created.
  • a series of citrate-based polymers with a wide range of properties such as controllable elasticity, biodegradability, shape-memory and antioxidant properties have been developed [26, 27; incorporated by reference in their entireties], and find use in embodiments herein.
  • polymers After methacrylation with glycidyl methacrylate, 2-aminoethyl methacrylate, or another suitbale compound, polymers are printed (e.g., via projection stereolithography, via Micro-CLIP, etc.) under the appropriate solvent and additive conditions.
  • compositions and methods to feasibly 3D print complex strut structures of biodegradable polymers on a micron scale are examples of the like.
  • Embodiments herein find use in, for example: endovascular stents and stent-related implants, 3D printed bio-medical implants containing patient-specific features, tailoring the mechanical properties of 3D printed devices through structural and materials design, related 3D printed products derived from biocompatible and/or biodegradable biomaterial inks, 3D printed bio-medical implants for sustained drug release, in vivo sensing platforms, etc.
  • the building materials of the 3D printed stent are precisely tailored to exhibit a compliant compressive, strength and flexibility with blood vessel and bare metal stent
  • the use of biodegradable biomaterial ink allows for the encapsulation of therapeutic agents, allowing, for example, the slow release of drugs from the bulk of the device (e.g., stent) in contrast, to the state-of-the-art coating method to coat the drug on the surface of stent struts.
  • a biomaterial ink comprises a curable (e.g., chemically-curable, photo-curable, etc.) polymer material.
  • the biomaterial ink comprises a polymer component displaying one or more curable (e.g., chemically-curable, photo-curable, etc.) substituents; upon exposure of the biomaterial ink to curing conditions, the biomaterial ink is converted from a pre-polymer into an insoluble, crosslinked polymeric material.
  • compositions and composites (e.g., biomaterial ink and/or solid biomaterials produced therefrom) described herein comprise a polymeric component.
  • a polymeric component comprises a polymer selected from a polyester, poly(diol citrate) (e.g., poly(butanediol citrate), poly(hexanediol citrate), poly(octanediol citrate), poly(decanediol citrate), poly(dodecanediol citrate), poly(hexadecanediol citrate), etc.), poly(hydroxyvalerate), poly(lactide-co-glycolide), poly(hydroxybutyrate), poly(hydroxybutyrate-co-valerate), polyorthoester, polyanhydride, poly(glycolic acid), poly(glycolide), poly(L-lactic acid), poly(L-lactide), poly(D,L-lactic acid), poly(D,L-lactic acid), poly(
  • a polymeric component comprises a citric acid-based polymer.
  • a polymer is the polyesterification product of one or more acids (e.g., succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, dodecanedioic acid, shorter or longer linear aliphatic diacids, citric acid, isocitric acid, aconitic acid, propane-1,2,3-tricarboxylic acid, trimesic acid, itaconic acid, maleic acid, etc.) and one or more diols or triols (e.g., polyethylene glycol, glycerol, linear aliphatic diol (e.g., butanediol, hexanediol, octanediol, decanediol, dodecanediol, and shorter or longer linear aliphatic di
  • a polymer is the polyesterification product of at least citric acid and one or more linear aliphatic diols (butanediol, hexanediol, octanediol, decanediol, dodecanediol, or any linear aliphatic diol from about 2-20 carbons in length).
  • a polymer may comprise only citric acid and linear aliphatic diol components or may further comprise additional monomer components (e.g., sebacic acid, polyethylene glycol, glycerol, etc.).
  • a polymer comprises additional substituents or functional groups appended to the polymer (e.g., ascorbic acid, glycerol, a NONOate group, etc.).
  • a polymeric component comprises citric acid as a monomer (e.g., along with a diol monomer).
  • Citric acid is a reactive tricarboxylic acid that is part of the Krebs cycle and has been used as a key reactant monomer for the synthesis of polydiolcitrates with a wide range of properties and uses (Yang, J., et al., Synthesis and evaluation of poly(diol citrate) biodegradable elastomers. Biomaterials, 2006. 27(9): p. 1889-98; U.S. Pat. No. 8,772,437; U.S. Pat. No. 8,758,796; U.S. Pat. No. 8,580,912; U.S.
  • a polymeric component is a poly(diol citrate), for example, those described in U.S. Pat. No. 8,911,720; herein incorporated by reference in its entirety.
  • derivatives of such poly(diol citrates) are provided.
  • a pre-polymer of citric acid and diol is formed (e.g., by reaction at about 140° C. or other suitable conditions).
  • a pre-polymer is reacted with one or more additional compounds to produce a functionalized (e.g., methacrylated) pre-polymer.
  • the curable polymer component of a biomaterial ink comprises a polymer displaying one or more curable (e.g., chemically-curable, photo-curable, etc.) groups.
  • a curable group is or comprises a methacrylate or acrylate group.
  • a curable group is or comprises N-Vinylpyrrolidone (NVP) or styrenestyrene.
  • a pre-polymer e.g., of poly(diol citrate)
  • a modifying group e.g., at about 40-100° C.
  • suitable reactant for modifying the poly(diol citrate) pre-polymer is glycidyl methacrylate or 2-aminoethyl methacrylate.
  • poly(diol citrate) and glycidyl methacrylate (or 2-aminoethyl methacrylate) are reacted in the presence of tetrahydrofuran and imidazole.
  • Other substituents e.g., other than glycidyl methacrylate
  • the poly(diol citrate) e.g., alone or with glycidyl methacrylate
  • other polymer components may be methacrylated.
  • acrylate group is displayed on the polymer or pre-polymer to produce a curable polymer for a biomaterial ink.
  • a citric acid-based, curable polyester comprises:
  • R is selected from H, a poly(diol citrate), and a curable group (e.g., photo-curable group (e.g., methacrylate group)); wherein R′ is selected from H, and a poly(diol citrate); wherein m is 2 to 20; and wherein at least one R is a curable group (e.g., photo-curable group (e.g., methacrylate group)).
  • a curable group e.g., photo-curable group (e.g., methacrylate group)
  • the citric acid-based polyester comprises:
  • R is selected from H, a poly(diol citrate), and a curable group (e.g., photo-curable group (e.g., methacrylate group)); wherein R′ is selected from H, and a poly(diol citrate); wherein m is 2 to 20; wherein n is 1 to 1000, and wherein 1-100% (e.g., 1%, 2%, 5%, 10%, 15%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 99%, 100%) of R groups are a curable group (e.g., photo-curable group (e.g., methacrylate)).
  • at least one R group comprises a methacrylate.
  • the citric acid-based polyester comprises:
  • the citric acid-based polyester comprises: the citric acid-based polyester comprises:
  • n is 1 to 1000. In some embodiments, m is 6 to 14.
  • methods of preparing methacrylated poly(diol citrate) comprising: a) synthesizing a prepolymer of citric acid and an aliphatic diol; and b) reacting the prepolymer with glycidyl methacrylate or 2-aminoethyl methacrylate.
  • the aliphatic diol is HO(CH 2 ) z OH, wherein z is 2-20.
  • a biomaterial ink in addition to a curable (e.g., photocurable) polymer component, comprises one or more of: a suitable solvent, a photoinitiator, a co-initiator, a free-radical quencher, a UV-absorber, etc.
  • suitable additional components of a biomaterial ink include ethyl acetate, 1-butanol, Diethyl adipate, 1,6-hexanediol diacrylate, Diethyl fumarate, Irgacure 819, 2-hydroxy-2-methylpropiophone (Homp), Camphorquinone, 4-ethyl-N,N-dimethylaminobenzoate, dyes such as Yellow 5 and Sudan 1, etc. Additional components will be understood in the field.
  • a biomaterial ink comprises one or more non-curable polymers or other materials, in addition to the photo-curable polymer component.
  • a composite e.g., noncovalently association
  • the non-curable component is stabilized within the composite by the cured polymer. Therefore, in some embodiments, biomaterial inks and the cured composites thereof may comprise curable (or cured) polymer component and one or more additional compounds, oligomers, polymers, hydrogels, thermosets etc.
  • biomaterial inks may comprise one or more biodegradeable polymers to form a composite material.
  • suitable biodegradeable polymers include, but are not limited to: collagen, elastin, hyaluronic acid and derivatives, sodium alginate and derivatives, chitosan and derivatives gelatin, starch, cellulose polymers (for example methylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, cellulose acetate phthalate, cellulose acetate succinate, hydroxypropylmethylcellulose phthalate), poly(diol citrate) (e.g., poly(octanediol citrate), etc.), casein, dextran and derivatives, polysaccharides, poly(caprolactone), fibrinogen, poly(hydroxyl acids), poly(L-lactide) poly(D,L lactide), poly(D,L-lactide-co-glycolide), poly(L-lactide-
  • Non-polymer components include, but are not limited to a bioceramic (e.g., hydroxyapatite, tricalcium phosphate, etc.), nanoparticles (e.g., iron oxide, zinc oxide, gold, etc.), etc.
  • a bioceramic e.g., hydroxyapatite, tricalcium phosphate, etc.
  • nanoparticles e.g., iron oxide, zinc oxide, gold, etc.
  • the curable (or cured) polymer comprises at least 10% (e.g., 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 98%, 99%, 100%) of the biomaterial ink and/or the resulting cured biomaterial.
  • the aforementioned percentages may be wt % or molar %.
  • many characteristics of the devices made with the materials and methods described herein are customizable. For example, to enable visibility of stents in the operating room, the radiopacity if the materials was considered. To enable radiopacity of stents (or other devices and implants), a large variety of possible materials could be used. In experiments conducted during development of embodiments herein, visipaque and Iodixanol have been incorporated devices (e.g., stents).
  • a stent exhibiting radiopacity blocks the view of a variety of scanning techniques that doctors use to determine the extent of restenosis. Since the device and stents herein will absorb into the body, restenosis rates are more easily monitored to determine if and when an additional follow-up procedure is necessary to protect the patient's health.
  • devices comprise materials to serve as contrast agents. This allows the devices to be monitored by various biophysical techniques, such as x-ray, magnetic resonance imaging (MRI), positron emission tomography (PET), computed tomography (CT), or single-photon emission computed tomography (SPECT).
  • MRI magnetic resonance imaging
  • PET positron emission tomography
  • CT computed tomography
  • SPECT single-photon emission computed tomography
  • Any suitable contrast agent could be incorporated into the materials and devices described herein.
  • an iodinated contrast agent is incorporated into the materials and devices, such as one selected from the group consisting of iohexyl, iopromide, ioversol, ioxaglate and iodixanol.
  • agents may be incorporated into the biomaterial inks, materials and devices herein. These agents may be covalently attached to a component of the ink (e.g., the polymer component), embedded within the material, coated onto a device, etc. Suitable agents include, but are not limited to: anticoagulants (e.g., heparin, Coumadin, protamine, hirudin, etc.), antithrombotic agents (e.g., clopidogrel, heparin, hirudin, iloprost, etc.), antiplatelet agents (e.g., aspirin, dipyridamole, etc.), anti-inflammatory agents (e.g., methylprednisolone, dexamethasone, tranilast, etc.), anti-proliferative/immunosuppresive agents (e.g., trapidil, tyrphostin, rapamycin, FK-506, mycophenolic acid), cytostatic drugs (e.g.
  • an mPDC base polymer, and any polydiolcitrates or methacrylated poly(diol citrates), are intrinsically antioxidant, which was confirmed by incubating mPDC (50 mg/mL) in 2,2′-azino-bis(3-ethylbenzothiazoline-6-sulphonic acid) or ABTS radical solution. mPDC slowly neutralized free radicals over time with 70% scavenged after 14 days ( FIG. 22 -Left). To assess the biocompatibility, UV-cured mPDC films were sterilized and seeded with vascular smooth muscle cells. Cells could attach and spread and showed excellent viability after 3 days of cell culture ( FIG. 22 -Center).
  • 3D-printed stents composition: 50% DEF, 47.78% mPDC, 2.2% Irgacure 819, 0.02% Sudan I
  • degraded over time upon incubation in PBS at 37 C with approximately 25% degraded after 6 months ( FIG. 22 -Right).
  • systems, devices, and methods are provided for fabricating biomaterial devices (e.g., implants, stents, etc.) of defined shapes and dimensions from a curable (e.g., photo-curable) biomaterial ink.
  • a curable biomaterial ink e.g., photo-curable
  • P ⁇ LS projection micro-stereolithography
  • micro-CLIP micro-continuous liquid interface production
  • Any suitable systems, devices, and methods for the controlled application and of biomaterial ink and conversion of the biomaterial ink into a biomaterial device is within the scope of embodiments herein.
  • Exemplary systems and processes, all or a portion of which may be utilized in embodiments herein, are described in connection with the biomaterial inks and device-production embodiments herein.
  • systems, methods, and devices from laser scanning stereolithography techniques are utilized.
  • curing between polymers is induced by micro-stereolithography, under the action of light.
  • a laser scanning unit exposes a defined area on the surface of the biomaterial ink, in a desired pattern, and in that way, with a given depth of penetration, hardens a layer of the pattern to be produced into a solid biomaterial.
  • a displacement unit in the z-direction provides that the substrate is lowered layer by layer by the defined layer thickness or the laser focus is raised.
  • the biomaterial ink over the previously produced solid biomaterial layer. This process is repeated until the desired structure is produced.
  • systems, methods, and devices from projection micro-stereolithography techniques are utilized (See, e.g., Example 1).
  • Projection micro-stereolithography (P ⁇ SL) adapts 3D printing technology for micro-fabrication.
  • Digital micro display technology provides dynamic stereolithography masks that work as a virtual photomask. This technique allows for rapid photopolymerization of an entire layer with a flash of UV illumination at micro-scale resolution.
  • the mask controls individual pixel light intensity, allowing control of material properties of the fabricated structure with desired spatial distribution.
  • the dynamic mask defines the beam.
  • the beam is focused on the surface of a UV-curable polymer resin through a projection lens that reduces the image to the desired size.
  • the stage drops the substrate by a predefined layer thickness, and the dynamic mask displays the image for the next layer on top of the preceding one. This proceeds iteratively until complete.
  • P ⁇ LS techniques which may be employed, alone or in combination with other 3D printing and/or additive manufacturing systems and processes are further described in Zheng et al. Rev Sci Instrum. 2012 December; 83(12):125001; which is incorporated by reference in its entirety.
  • systems, methods, and devices from direct inkjet 3D printing techniques are utilized.
  • Direct inkjet printing systems fabricating a part/device by an additive manufacturing process.
  • an ink delivery system operative to circulate the biomaterial ink, a printhead associated with the ink delivery system, dispenses the biomaterial through one or more nozzles based on a defined pattern (e.g., CAD defined pattern) onto a surface for receiving the dispensed biomaterial ink one layer at a time.
  • a defined pattern e.g., CAD defined pattern
  • the dispensed ink is exposed to a cure-induced (e.g., light) in order to produce a layer of solid biomaterial on the receiving surface.
  • the part/device is formed from a plurality of layers, as the biomaterial ink is dispensed from the printhead and the ink is cured in successive layers.
  • P ⁇ LS techniques which may be employed, alone or in combination with other 3D printing and/or additive manufacturing systems and processes are further described in Müller et al. Prod. Eng Res. Devel. (2014) 8:25-32; which is incorporated by reference in its entirety.
  • systems, methods, and devices from Continuous Liquid Interface Production (CLIP) and/or Micro Continuous Liquid Interface Production (Micro-CLIP) techniques are utilized.
  • CLIP the continuous process begins with a pool of photo-curable biomaterial ink. A portion of the pool bottom is transparent (“window”) to light (e.g., UV light). A light beam shines through the window, illuminating a precise cross-section of the object. The light converts the biomaterial ink into a sold biomaterial. The formed object rises slowly enough to allow the ink flow under and maintain contact with the bottom of the object.
  • an oxygen-permeable membrane lies below the ink, creating a “dead zone” (persistent liquid interface) preventing the ink from attaching to the window.
  • P ⁇ LS techniques which may be employed, alone or in combination with other 3D printing and/or additive manufacturing systems and processes are further described in Dendukuri, D. (2006). Nature Materials 5, 365-369 (2006); which is incorporated by reference in its entirety.
  • devices and components produced by the systems, materials, and methods herein find particular utility in biomedical applications.
  • devices or components/parts of devices for implantation into a subject are produced by the systems and methods described herein.
  • the permanence/impermanence of the particular device may be tailored (e.g., biodegradation over 1 week, 2 weeks, 1 month, 2 months, 3 months, 4 months, 6 months, 8 months, 1 year, 2 years, 3 years, 5 years, 10 years, or ranges therebetween).
  • Embodiments herein are not limited by the type of device or implant, or component/part thereof, that is produced by the systems, materials, and methods described herein.
  • Exemplary implants, devices, etc. that may be manufactured by the systems, materials, and methods described herein, or may have a part or components that may be manufactured by the systems, materials, and methods described herein, include, but are not limited to: stents, stent-grafts, grafts, vascular grafts, shunts, screws, nails, threads, clasps, tubes, catheters, patches, plates, sheets, meshes, ports, rings, prostheses, contact lenses, ocular implants, cardiovascular implants, pacemakers, orthopedic implants, sockets and counterparts, etc.
  • materials and devices are provided with self-expanding material properties, shown in FIG. 20 .
  • the devices e.g., stents
  • the self-expanding character is useful for implantable devices (e.g., stents), for example, for derives that are implanted into peripheral arteries, especially when those arteries are near areas of the body that can be collapsed by external forces such as the arteries within the thigh and near the knees.
  • devices comprising balloon-expandable designs.
  • balloon-expandable devices comprise a PLLA-based material that is plastically deformable.
  • Balloon-expandable stents for example, are used almost exclusively in cardio implants, and are preferred in that field due to their improved flexibility and stronger radial strength.
  • compositions and methods described herein may find use with any suitable photo-polymer based additive manufacturing devices/techniques (e.g., Laser Scanning Stereolithography, Projection Stereolithography, Ink-Jet Printing, Continuous Liquid Interface Production (CLIP), etc.), two printer types are exemplified below to demonstrate successful fabrication, imaging and mechanical testing of the designs to validate them. Exemplary methodologies and utilities of each printing type are explained in the examples below.
  • photo-polymer based additive manufacturing devices/techniques e.g., Laser Scanning Stereolithography, Projection Stereolithography, Ink-Jet Printing, Continuous Liquid Interface Production (CLIP), etc.
  • CLIP Continuous Liquid Interface Production
  • a biodegradable biomaterial ink was formulated with biodegradable methacrylated poly(diol citrate)s and enables rapid fabrication of endovascular devices (e.g., stents) via projection microstereolithography technique.
  • endovascular devices e.g., stents
  • stents with various microstructures were printed in a resolution of 20 um using CAD modeling.
  • mPDC stent showed a compliant compressive strength and flexibility.
  • numerical simulation showed the experimental results differed by approximately a factor of 5, the 350 um stent best approximates the Nitinol BMS stent.
  • Citric acid 76.8 g; Sigma
  • 1,12-dodecanediol 40.4 g; Sigma
  • the viscous poly(1,12-dodecanediol citrate) (PDC) pre-polymer is dissolved in 100-150 ml ethanol and purified by precipitation in 1000 mL of deionized water (Millipore water purification system), then freeze-dried for at least 72 hours.
  • mPDC was purified using 900 mL of deionized water twice, then centrifuged in 50 mL vials for 5 minutes at 3500 rpm followed by freeze drying for 24 hours.
  • the purified mPDC polymer was characterized using a Bruker Ag500 NMR spectrometer at ambient temperature, using DMSO-d6 as solvent, and tetramethylsilane (TMS) as the internal reference.
  • the viscous mPDC polymer was diluted with different chemicals such as ethyl acetate (Anhydrous, 99.8%; Sigma), 1-butanol (ACS reagent, >99.4%; Sigma), Diethyl adipate (ReagentPlus®, 99%; Aldrich), 1,6-hexanediol diacrylate (Technical grade, 80%; Aldrich) and Diethyl fumarate (98%; Aldrich), 0.1-5wt % amounts of initiators such as Irgacure 819, 2-hydroxy-2-methylpropiophone (Homp) and Camphorquinone were formulated into mPDC solution for curing at different wavelengths.
  • ethyl acetate Anhydrous, 99.8%; Sigma
  • 1-butanol ACS reagent, >99.4%; Sigma
  • Diethyl adipate ReagentPlus®, 99%; Aldrich
  • 1,6-hexanediol diacrylate
  • Viscosity changes as a function of shear rate were assessed via rheometry.
  • P ⁇ SL Projection microstereolithography
  • FIG. 7 An exemplary process flow is depicted in FIG. 7 .
  • a photo-curable biomaterial ink was formulated as described in the section below.
  • the CAD structure is sliced into a series bitmap images using a MATLAB code developed specifically for this system.
  • the UV absorber and light intensity concentration is tuned to obtain a curing depth of 20 microns, determining the necessary slicing layer thickness.
  • the silicon wafer is then aligned with the top of the biomaterial ink layer, and the 160 liter P ⁇ SL chamber is filled with nitrogen gas. This reduces the concentration of oxygen within the chamber and ensures optimal solidification and resolution of the photo-curable biomaterial ink. Afterwards, the layer building process begins.
  • the first sliced bitmap image is displayed on the dynamic mask (in this case, a 1400 ⁇ 1050 pixel array), and the wafer drops by 20 microns. The system then waits for 30 seconds for the biomaterial ink to settle.
  • the UV lamp is turned on for 20 seconds, reflects off a beam splitting mirror, passes through a reduction lens and finally projects onto the surface of the biomaterial ink in high resolution, with each pixel corresponding to 7.1 ⁇ 7.1 ⁇ m 2 repeats for each bitmap layer in the fabrication.
  • the micro-structure is then removed from the P ⁇ SL machine, cleaned with isopropyl alcohol (IPA), dried under a low flow rate nitrogen gun. At this point, the biomaterial ink within the structure has not completely solidified. To finish the curing process and bring the biomaterial ink to its final state, the structure is further exposed to UV for post-curing.
  • IPA isopropyl alcohol
  • Stent design with various microstructures were prepared using the SOLIDWORKS CAD software (Waltham, Mass.). Sinusoidal formed wire, helix wrap and meshed tube was created and printed along the circumference layer-by-layer with length ⁇ outer diameter ⁇ thickness. Various parameters such as 300 um, 350 um, 400 um and 500 um in thickness or 9.0 mm, 16 mm and 21 mm in length were investigated. Typically, a stent pattern was chosen to be a triangular truss structure along the circumference with each new row connected via vertical supporting rods, as shown in FIG. 3 a . Each new row was shifted to allow the lowest point of the upper row to be in line with the highest point of the bottom row. These points were then connected by vertical beams that gives the appearance of hexagonal holes across the face of the cylinder. To avoid misalignment and a floating point at the low point of the top row, vertical support rods were placed at low and high point section for fabrication.
  • the rods with smaller cross section act as removable support structure that were removed after fabrication was completed, outer diameter of stent was given a set value of 5.20 mm. Stent strut thickness was set to 350 um, the individual “true support” stent rod diameter was also set at 350 um and a height of 550 um tall. The “removable support” material rods were set to a value of 100 um with a height of 300 um. Further support rods of 150 um diameter and 300 um tall were placed at the bottom of the stent to allow easy removal from the base. The entire stent was built on a square base of 5.5 mm ⁇ 5.5 mm by 500 um tall. This overall design was initially chosen in order to verify the capability of the P ⁇ SL system to manufacture such structures as stents. Optimization to this design and other design changes was performed.
  • a three-point bend test apparatus (a cylindrical actuator in the middle of two cylindrical end-supports at a distance of 20 mm) was used for flexibility testing, which was performed according to ASTM F2606-08 on a MTS Sintech 20/G Universal Testing Machine with 210 N load cell at a crosshead rate of 10 mm/min (Sinotech, Portland, Oreg.). The maximum bending angle was set at 48°.
  • Citric acid is a multifunctional monomer in the Kreb's cycle that is easily reacted with various diols to form a crosslink elastomer in the absence of exogenous catalysts (ref. 26; incorporated by reference in its entirety).
  • the synthesized PDDC prepolymer was uncrosslinked and was dissolvable in several solvents such as ethanol, acetone, dioxane, etc (ref. 28; incorporated by reference in its entirety).
  • glycidyl methacrylate was used in an epoxide ring-opening reaction to attack the unreacted carboxylic groups of citric acid using imidazole as a catalyst.
  • Methacrylate was successfully introduced to the PDDC backbone.
  • a novel mPDC polymer was obtained as determined by 1 H NMR spectrum with evidence of proton peaks for citrate residues (1) and methacrylate residues (5 and 6) ( FIG. 1 ).
  • the multiple peaks at 2.79 ppm were assigned to the protons in —CH2— from citric acid, and the peak at 1.84 ppm was assigned to —CH3 in methacrylate unit.
  • the molar composition of mPDC calculated from the signal intensities of both protons was approximately 1:1 of citric acid/methacrylate.
  • mPDC polymer immediately forms a solid by photopolymerization after mixing with a photoinitiator as shown in FIG. 1 .
  • mPDC polymer is easily dispersed and formulated in different chemicals such as ethanol, acetone, dioxane, ethyl acetate, 1-butanol, Diethyl adipate, 1,6-hexanediol diacrylate and Diethyl fumarate, etc.
  • mPDC viscosities do not change significantly in a shear rate from 1 to 150 l/s, at 15.5 ⁇ 0.4 Pa ⁇ s as shown in FIG. 2 c .
  • the mPDC solution Upon adding different amounts of ethyl acetate, the mPDC solution remains flowing stable, the viscosities remarkably decrease over shear rate with the increasing ethyl acetate, from 8.0 ⁇ 0.5 Pa ⁇ s in 5 wt % to 1.50 ⁇ 0.04 Pa ⁇ s in 15 wt %. However, all the viscosities of the polymer and solution decrease over temperature, heating can increase the flowability of both polymer and solution.
  • FIG. 2 a showed the UV/Vis absorption of different initiators such as Irgacure 819, Camphorqinone and 2-hydroxy-2-methylpropiophone separately in 370 nm, 470 nm and 340 nm, with the concentration dependence.
  • the mPDC stent in 0.5 mm thickness showed complete compliance with BMS in compressive strength in FIG.
  • Projection microstereolithography printer design was based on digital micromirror device (DMD, Texas Instrument) as a dynamic mask at 1400 ⁇ 1050 pixels that is the core of this technique to use a spatial light modulator.
  • the modulated light was transferred through a reduction lens (CoastalOpt 60 mm UV-VIS-NIR lens, JENOPTIK Optical System Inc) to the surface of biomaterial ink with the reduced feature sizes, each pixel in the dynamic mask is focused down from original dimensions (object size) of 10 um ⁇ 10 um to an image size of 7.1 um ⁇ 7.1 um, the magnification is approximately 1.4.
  • the biomaterial ink can be cured at a 2D pattern in a single exposure and stacked in a series of closely spaced horizontal planes programmed by a 3D CAD model.
  • the intensity of UV light is controlled by the current input into the system with 0.4 A at 405 nm, the measured intensity is 0.03 mW.
  • the curing time for HDDA stent is 12 seconds per layer and 20 seconds per layer for mPDC stent.
  • the biomaterial ink enables printing the stents with high resolution of 7 um pixel in a curing depth of 20 um.
  • the cured biomaterial ink has strong enough mechanical properties to enable 350-400 um struts over a 21 mm stent design height, as shown in FIG. 3 c - d and FIG. 4 , each layer is 20 um in depth with precise edges.
  • FIG. 3 c - d and FIG. 4 various microstructures in the stents were also showed in FIG. 3 c - d and FIG. 4 .
  • Sinusoidal wire and fiber mesh were stacked in circular and rectangular layers with 20 um height.
  • SEM images showed sinusoidal stent was interconnected with bridges in 0.55 mm as designed as vertical support rods.
  • FIG. 5 d A typical displacement field from a 400 um thick stent is presented in FIG. 5 d . From an applied force of 0.5N onto the 400 um stent, the resulting maximum displacement of 7.945 mm was observed where forces were applied. The displacement on the opposite end of the stent was 3.783 mm. For all three stent thicknesses, the maximum displacement was plotted against the force applied to the stent ( FIG. 5 c ). For increasing stent thickness, the necessary applied force to displace the stent increases.
  • the primary properties analyzed in these simulations were the range of forces that these stents are predicted to be usable.
  • the stent was considered “unusable” when the point of maximum displacement is within 1 mm from the point on the opposite side of the circumference of the stent. This was determined from the following equation:
  • the parallel-plate compression was simulated on the three stent designs. With increasing force, there is nonlinear contact between the plates and the new deformed surface of cylinder.
  • the parallel-plate compression analysis was done for this study by fixing a slim region along the length of the cylinder be fixed. Particular faces on the cylinder's opposite side were subjected to equal forces. As with three-point bending, the range of forces that the stents were “usable” were analyzed ( FIG. 6 a ) and the Maximum Usable Applied Force was plotted in relation to stent wall thickness ( FIG. 6 b ). With increasing stent thickness, the necessary force to cause deformation of the stent walls increased. The numerical results and the experimental results differed by approximately a factor of 5. A scaling factor of 5 was used in order to compare the experimental results and the numerical results.
  • FIGS. 6 a and 6 c represent Applied Forces multiplied by the scaling factor.
  • the “HDDA” stent used for the experimental tests was a design that was 500 um in thickness for both the stent walls and all supporting rods. This slightly differs from the design that is numerically evaluated.
  • the design that is being evaluated numerically has some support structures of (100 um).
  • the HDDA stent needed approximately 4N of applied force to cause displacement.
  • the 500 um design needed approximately 3.5N of force. This difference could be attributed to the inclusion of smaller 100 um support rods.
  • the 350 um stent best approximates the Nitinol BMS stent. In both cases, approximately 1N of force is necessary to compress the structure 2 mm.
  • Micro-CLIP manufacturing method is based on a similar methodology as Projection Micro-Stereolithography.
  • the Micro-CLIP system is capable of printing up to 200 times faster than projection stereolithography method.
  • Micro-CLIP printer devices were generated at the necessary scale for low-volume manufacturing.
  • PuSL projection stereolithography
  • 16 hours of time were required for a single print.
  • Micro-CLIP a new 20 mm length stent can be printed in just five minutes.
  • the slowest prints tested took only seventy minutes, which is nearly 15 times faster than the PuSL system for a high resolution object of 1000 layers. This time is further reducible through the use of properly optimized material, light source, and dead zone.
  • This technology has additional advantages including the ability to work with a broader array of polymer materials and each print has isotropic material properties.
  • Micro-CLIP has weaker provided mechanical properties under compression.
  • Micro-CLIP additive manufacturing provides for the fabrication of microstructures from a photo-curable biomaterial ink in a layer-by-layer fashion directly from a 3D CAD design. Each layer is cured in a single exposure using a digital micromirror-device (DMD) as the dynamic mask for the UV light. This differs from the P ⁇ SL system which uses a liquid crystal display. The liquid crystal display is not able to withstand the high power UV required for the Micro-CLIP process. This allows for a dramatic reduction in fabrication time compared with conventional 3D printing processes, which fabricate 3D structures in a point-by-point scanning fashion. In addition to fabrication of an entire surface area at once, CLIP operates under nearly continuous motion.
  • DMD digital micromirror-device
  • the fabricated part is typically dipped back into the liquid resin bath and then raised so that only a single ⁇ 5-20 um layer of liquid is on top of the part, then time is allowed for the material to settle, a process that can take 30 seconds to two minutes per layer depending on the material viscosity. That entire process is eliminated in CLIP.
  • CLIP With CLIP, the platform moves upwards at a nearly constant speed, only stopping for 10 ms-100 ms between each layer, dramatically reducing part print speed. Additionally, a higher intensity of UV light is used which enables photocuring each layer of the part in dramatically less time.
  • a photo-curable biomaterial ink Prior to device (e.g., stent) fabrication, a photo-curable biomaterial ink was formulated as described in the section below.
  • the CAD structure is sliced into a series of bitmap images using a MATLAB code developed specifically for this system.
  • the UV absorber and light intensity concentration were tuned to obtain a curing depth of 20 microns to tune the finalized surface finish of the part.
  • the Teflon AF2400 thin film was aligned to be placed 20 um below the focal plane of UV intensity.
  • the build platform then drops down until it comes in contact with the Teflon AF2400 thin film, contact is determined via a force sensor built into the platform.
  • Teflon AF2400 thin film The purpose of the Teflon AF2400 thin film is to control the oxygen flow rate that makes contact with the liquid resin. Oxygen inhibits the photo-polymerization reaction and by allowing just a small amount into the bath a dead-zone forms.
  • the printing process then begins and the first sliced image is displayed on the digital micromirror devices (in this case a 1980 ⁇ 1050 pixel array).
  • the system begins moving upwards at the desired user controlled speed (80 um/s for example) until the system has moved upwards 20 um.
  • the system then briefly stops, switches images to the second sliced image, waits for 10-100 ms to ensure a full switch of the image, and then begins moving again at the user controlled speed.
  • Speed, UV intensity, and image are dynamically controllable and modulatable at each individual layer of the print.
  • Layer thickness does not have to be 20 um, it can be as low as 100 nm. This process continues, with the platform continuing to move up and new images continuing to be displayed until the entire part is completed.
  • the light In terms of the light path when the UV LED is turned on, the light first passes through a collimating lens, through a light gate and then reflects off a digital micro-mirror device which contains millions of tiny mirrors. The reflected light passes back through the light gate, through a focusing lens and beam-splitter and off a 90 degree mirror before ending at the focal plane with each pixel corresponding to 7.2 ⁇ 7.2 um ⁇ 2.
  • the micro-structure was then removed from the machine, excess material was cleaned off with a chem-wipe and the part was left in a dionized water bath for a few hours to remove any excess material. To improve mechanical strength the parts were then removed from the water bath, dried under a nitrogen gun and post-cured under an intensity of 350 mW/cm 2 for 6 minutes (3 minutes on each side).
  • Resolution of the fabrication systems is affected by several variables from both the fabrication system and the fabrication material. Potential variables include the following: speed of fabrication, light intensity, amount of pause at each fabrication layer (exposure time), concentration of UV absorber in material, and concentration of photoinitiator in the material.
  • Several fabrication tests were performed that varied several of the parameters listed above. Shown in FIG. 10 are the dimensional differential vs. light intensity plots from four tests that were performed. For these tests, the fabricated dimensions of the stents were compared against the intended stent design dimensions. “Base” stent design has an intended dimension of 151.4 um strut thickness in the axial and lateral (planar) directions. Dimensional differential is the percentage difference between the actual fabricated dimension and the intended dimension.
  • Values below the X-axis represent the fabricated dimension is a certain percentage smaller than intended (underexposure) and values above the X-axis representing the fabricated dimension being a certain percentage larger than intended (overexposure).
  • the X-axis represents fully accurate dimension resolution (correct exposure).
  • Light intensity was measured as the percentage of the system's maximum intensity.
  • Photoinitiator and UV absorber used in these tests were Irgacure 819 and Sudan 1, respectively.
  • Exposure time pause of machine at each fabrication layer was either 1 ms or 10 ms. Fabrication speed was fixed at 5 um/s. Fabricated dimensions were acquired from scanning electron microscopy and imageJ software and represent an average along the length of the stent. From these tests areas where accurate resolution could be achieved were identified for each material.
  • FIG. 9( a ) represents a test with a biomaterial ink resin containing 2.2% photoinitiator, and 0.02% absorber concentrations. The exposure time for this set of stents was 1 ms. From this test it was observed that the correct axial exposure was achieved at approximately 13% or 14% intensity. Correct lateral exposure was achieved at 17-18% light intensity.
  • FIG. 9( b ) represents a test with the absorber concentration increased to 0.04% and exposure time increased to 10 ms. At 10% light intensity, axial differential was only approximately 5%, a decrease to 8% or 9% light intensity could potentially be give dimensional accuracy. Correct lateral exposure appears to be achievable at 15% light intensity. In the test represented by FIG.
  • liquid polymer materials function well within these additive manufacturing processes.
  • Solvents including Ethanol and Ethyl Acetate have been used to replace Diethyl Fumarate in the material composition of each individual stent. Because Ethanol has a lower viscosity than Diethyl fumarate, less Ethanol is necessary within the final material to match the viscosity requirements for printing. Ethanol and/or Ethyl Acetate improve the biocompatibility of the process.
  • the UV Absorber Sudan I can be changed to Benzotriazol, a UV absorber that is nearly transparent in the visible spectrum and causes the printed object to look clear to the human eye.
  • photo-initiators are compatible with this process including but not limited to Irgacure 819, Irgacure 651, Irgacure 369, Irgacure 184, Irgacure 2959, Irgacure 1173, 2-hydroxy-2-methylpropiophone (Homp) and Camphorquinone.
  • Transparent materials are being used to create a look of cleanliness for both the surgeon and the patient and improve the aesthetic quality of the device.
  • AM processes allow for excellent design flexibility and tunability. With both P ⁇ SL and CLIP processes a base stent design can be experimentally tested and quick design iterations are possible.
  • the ability to free form fabricate structures with very high resolution within the span of at most a few hours (P ⁇ SL) to as low as a few minutes (CLIP) allows for very fast direct experimental testing and design iteration.
  • P ⁇ SL P ⁇ SL
  • CLIP a few minutes
  • these manufacturing processes accommodate changes in a base stent design to a complete custom design. If large radial strength is needed, wall and strut thicknesses are editable. If more flexibility is needed, strut connector design is edited.
  • AM processes allow for a specially made stent to fit the particular vessel. While AM processes have certain advantages in terms of flexibility compared to other manufacturing processes, AM processes still have their own requirements. For stereolithography based manufacturing (scanning, projection, CLIP), each fabrication layer must be connected to a previous fabrication layer, a support fabrication post, or the build platform. If a design does not account for this requirement, the printed structure will have structural defects. To accommodate this requirement, current stent designs have the low point of each strut ring connected to some portion of the connector ring below it. Two designs that have been created and parallel-plate compression tested. Our “Base” design shown in FIG. 11 below and Arrowhead design in FIG.
  • FIG. 14 is a conceptual design that has not been mechanically tested yet.
  • the Base design was created to be closely packed to increase radial strength, while the “S” shaped connections were added to provide reasonable flexibility.
  • a base design was made similar to a design on the market. Designs made for patients can be tailored to suit the patient's needs.
  • a unit length of the “Base” stent design consists of 12 unit cell elements across the circumference of the stent. This unit length of the stent could then be added to one another until the desired full length was obtained.
  • Strut thickness of the Base design was set to be 151.4 um.
  • the angle between struts was set to be 60 degrees.
  • the stent wall was given a thickness of 500 um for the bulk of mechanical testing.
  • FIG. 12 shows the CAD drawings as well as SEM micrograph of the Arrowhead stent design. This design also has a 60 degree angle between struts. Connector thickness and smallest tested strut thickness was 150 um. Unit length of the stent consisted of 8 unit cells. Typical unit cell of this design is shown in FIG. 12( c ) . As with the base design, unit lengths of the Arrowhead design could be attached to one another in CAD software until desired length is obtained.
  • metamodels are created of how each design parameter affects the objective and constraint functions.
  • Constraint functions may be failure stresses, patient vessel geometric constraints, and fabrication constraints.
  • Metamodels may be created from data collected via FEM modeling or experimental data. Following is an example of parametric optimization performed on a stent design made during experiments conducted during development of embodiments herein is shown. A parametric flexibility optimization was performed on the Base design template to make a stent for more diverse applications. The previously described stents were mainly designed to favor strength rather than flexibility. Flexibility is a key component of stents, as vasculature may curve suddenly, and the stent needs to be able to be potentially inserted in variety of geometric areas.
  • the design variables that were varied for study were the strut angle ( ⁇ ) and the Connector Height (H).
  • the connector thickness (t) was given a fixed relationship with the Connector Height, with t being 20% of the height ( FIG. 14( a ) ).
  • Stress analysis was performed using ANSYS FEA software.
  • the objective function that was to be optimized was known as the Flexibility Metric (FM), which was defined as the integral of Moment vs. Curvature index graph (Pant, S.; Bressloff, N W; Limbert, G. Biomech. Model Mechanobiol . (2012) 11; incorporated by reference in its entirety).
  • FM represents a value to be minimized as it implies that for a particular curvature index a smaller applied moment is required.
  • Design of experiments was obtained via Latin Hypercubes in iSight optimization software, which gave 20 design points of interest. Nineteen of these points were created in CAD. The design space of ( ⁇ ) was chosen to be 40 and 110 degrees and the design space of “H” was chosen to be between 250 um and 1 mm.
  • FIG. 13( b ) A metamodel was created using iSight software and contour plot of the FM was made, which is shown above in FIG. 13( c ) .
  • the gray shaded region to the left of the graph showed where failure by exceeding the 10 MPa was likely.
  • the dark shaded elliptical region represents an area where a minimum of FM could be found.
  • This optimized design is shown in FIG. 14 below. This design was successfully fabricated.
  • this design differed from the “base” design by including thinner wall (400 um), slightly larger strut (200 um) and reduction in circumferential elements (8, rather than 12).
  • the radial strength of stent can be increased by increasing the UV intensity used during printing.
  • the radial strength decreases with an increase in Sudan I concentration, giving flexibility in strength by changing the UV absorber content.
  • FIG. 18 demonstrates that for the Arrowhead design the radial strength does not depend on the strut dimensions, but is strongly dependent on the wall thickness.
  • FIG. 19 indicates that biomaterial ink stents may be printed using an accelerator compound like EDAB.
  • EDAB accelerates the rate of radical formation for polymerization initiation.

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US20210346576A1 (en) 2021-11-11

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