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Physiological Load-Response in Synthetic Ligaments through Active Filament-Mixing Fabrication.

Joshua T Green1, Jonathan J Slager2, Mauricio Lopez3

  • 1College of Engineering, Department of Engineering Education and Leadership, The University of Texas at El Paso, 500 W. University Ave., El Paso, TX, 79968, USA. jtgreen2@utep.edu.

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Summary

This study demonstrates 3D printing of synthetic anterior cruciate ligament (ACL) tibial complexes with precise material properties for anatomical accuracy and load response. The novel fabrication method offers versatile applications for advanced medical training models.

Keywords:
Active filament-mixing fabricationFused filament fabricationLocal composition controlMusculoskeletal biomechanicsSynthetic tissueThermoplastics

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Area of Science:

  • Biomaterials Engineering
  • Additive Manufacturing
  • Musculoskeletal Biomechanics

Background:

  • Current medical trainers lack realistic musculoskeletal load responses.
  • Synthetic tissues with anatomical accuracy and tunable mechanical properties are needed.
  • Additive manufacturing offers potential for creating advanced anatomical models.

Purpose of the Study:

  • To fabricate synthetic anterior cruciate ligament (ACL) tibial complexes using active filament-mixing fabrication.
  • To achieve local composition control for matching tissue modulus of elasticity.
  • To create functionally graded transitions between ligament and bone tissues.

Main Methods:

  • Modeled synthetic tissues from magnetic resonance imaging (MRI) data for anatomical accuracy.
  • Fabricated synthetic ACL tibial complexes using active filament-mixing 3D printing.
  • Tested specimens at 30° flexion under tibial and anatomical load orientations.

Main Results:

  • Achieved anatomical accuracy in synthetic tissues.
  • Tibial orientation loading: ultimate load 287±37 N, stiffness 62.8±11 N/mm.
  • Anatomical orientation loading: ultimate load 312±6.5 N, stiffness 43.5±3.4 N/mm.

Conclusions:

  • The developed fabrication method is versatile, repeatable, and compatible with various thermoplastics.
  • While load response was less than cadaveric counterparts, the method shows promise for other tissues and joints.
  • This approach advances the creation of functional synthetic tissues for medical training and research.