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Related Experiment Video

Updated: Jan 24, 2026

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Identifying extractable profiles from 3D printed medical devices.

Joel D Rindelaub1, Zane Baird2, Bruce A Lindner3

  • 1School of Chemical Sciences, University of Auckland, Auckland, NZ.

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Summary

3D printing medical devices can alter chemical leachability. Post-printing annealing significantly reduces extractables, while brass nozzles increase lead detection in final device extracts.

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Area of Science:

  • Materials Science
  • Biomedical Engineering
  • Chemical Analysis

Background:

  • 3D printing enables personalized medical devices, but the chemical safety of printed materials requires thorough assessment.
  • Regulatory guidelines mandate risk assessments based on extractables, yet the impact of 3D printing on leachability is not fully understood.

Purpose of the Study:

  • To investigate the extractable profiles of 3D printed medical device materials.
  • To evaluate the chemical impact of the fusion deposition modeling (FDM) printing process on material leachability.
  • To assess the effectiveness of post-processing techniques like annealing on reducing extractable components.

Main Methods:

  • Analysis of extractable profiles from four different 3D printing materials, including a "FDA-approved" PLA.
  • Utilizing fusion deposition modeling (FDM) for device fabrication.
  • Investigating the effect of annealing procedures and brass printing nozzles on extractable composition.

Main Results:

  • The FDM printing process introduced unique chemical and physical signatures in material extracts.
  • Annealing reduced extractable components by up to 50-fold.
  • Brass nozzles correlated with increased lead (Pb) detection in extracts.

Conclusions:

  • 3D printing processes significantly influence the extractable profiles of medical device materials.
  • Annealing is an effective post-processing step to mitigate chemical risks associated with 3D printed medical devices.
  • Material characterization and risk assessment are crucial for the safe clinical application of 3D printed medical devices, with nozzle material being a key consideration.