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Additive Manufacturing of Polyhydroxyalkanoate-Based Blends Using Fused Deposition Modelling for the Development of

David Alexander Gregory1, Annabelle T R Fricker1, Peter Mitrev1

  • 1Department of Materials Science and Engineering, Faculty of Engineering, University of Sheffield, Sheffield S10 2TN, UK.

Journal of Functional Biomaterials
|January 20, 2023
PubMed
Summary

Additive Manufacturing (AM) using Fused Deposition Modelling (FDM) shows promise for creating patient-specific biomedical devices. Research explores biocompatible polymer blends for applications like implants and stents.

Keywords:
3D printingPolyhydroxyalkanoatesbiomedical devicesregenerative medicinethermoplastic polymerstissue engineering

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Area of Science:

  • Biomaterials Engineering
  • Medical Device Manufacturing
  • Additive Manufacturing

Background:

  • Additive Manufacturing (AM) is increasingly vital for biomedical applications.
  • Fused Deposition Modelling (FDM) is a cost-effective AM technique with potential for diverse medical devices.

Purpose of the Study:

  • To explore the application of FDM for fabricating various biomedical devices.
  • To design and prototype patient-specific implants using CT scan data.
  • To evaluate novel biocompatible and bioresorbable polymer blends for medical use.

Main Methods:

  • Proposed CAD designs for bone implants, tooth implants, tissue repair patches, nerve guidance conduits (NGCs), and coronary artery stents.
  • Fabricated proof-of-concept prototypes using a cost-effective FDM 3D printer.
  • Utilized a blend of Polyhydroxyalkanoates (PHA) and Poly(L-lactic acid) (PLLA) for filament production.
  • Characterized the tensile properties of the PHA/PLLA blend.

Main Results:

  • Demonstrated FDM's capability for creating patient-specific implants from CT scans, including structural reconstruction.
  • Characterization suggests the PHA/PLLA filament possesses suitable tensile properties for stents, NGCs, and bone scaffolds.
  • Proof-of-concept work indicates FDM's utility for soft tissue applications, though elastomeric MCL-PHAs may be required.

Conclusions:

  • FDM is a versatile and cost-effective technology for producing a wide range of biomedical devices.
  • PHA/PLLA blends show potential for load-bearing and structural biomedical applications.
  • Further development with elastomeric polymers is needed for specific soft tissue applications.