Influence of Material Selection on the Mechanical Properties of 3D-Printed Tracheal Stents for Surgical Applications

Endotracheal prosthesis placement is employed as a therapeutic intervention for tracheal lesions in cases where conventional surgical approaches are not feasible. The learning curve for endotracheal stent placement can vary depending on the type of stent, the training environment, and the clinician's prior experience; however, it is generally considered moderately complex. Inadequate practice can have serious consequences, as the procedure involves a critical area such as the airway. The main risks and complications associated with inadequate technique or improper execution can include stent migration, formation of granulation tissue or hyperplasia, tracheal or pulmonary infection, obstruction or fracture of the stent, hemorrhage and tracheal perforation, among others. The purpose of the present study is to summarize important information and evaluate the role of different material features in the 3D printing manufacturing of an appropriate tracheobronchial medical device, which should be as appropriate as possible to facilitate placement during surgical practice. A complex stent design was fabricated using three different biodegradable materials, polycaprolactone (PCL), polydioxanone (PDO), and polymer blend of polylactic acid/polycaprolactone (PLA/PCL), through additive manufacturing, specifically fused filament fabrication (FFF)3D printing. Parameter optimization of the 3D printing process was required for each material to achieve an adequate geometric quality of the stent. Experimental analyses were conducted to characterize the mechanical properties of the printed stents. Flexural strength and radial compression resistance were evaluated, with particular emphasis on radial force due to its clinical relevance in preventing collapse after implantation in the trachea. The results provide valuable insights into how material selection could influence device behavior during placement to support surgical requirements.