Fused deposition modeling significantly reduces bioburden

Area of Science:

• Biomedical Engineering
• Materials Science
• Microbiology

Background:

• Additive manufacturing (AM), specifically fused deposition modeling (FDM), offers potential for on-demand surgical instrument production in resource-limited settings.
• Conventional sterilization techniques can degrade the thermoplastics commonly used in FDM.
• Investigating the inherent high temperatures of FDM for bioburden reduction is crucial.

Purpose of the Study:

• To evaluate the efficacy of fused deposition modeling (FDM) high printing temperatures in reducing microbial contamination on 3D printed materials.
• To assess if FDM can serve as a preliminary sterilization step for surgical instruments.

Main Methods:

• Polycarbonate filament was inoculated with Escherichia coli and Staphylococcus aureus.
• Samples were 3D printed using FDM at two temperatures (260°C and 300°C).
• Printed samples and controls were cultured under various conditions (aerobic, anaerobic, fungal) for 14 days to assess sterility.

Main Results:

• A significant reduction in microbial contamination was observed in FDM printed samples (16.6% contamination) compared to controls (100% contamination) (p<0.01).
• No statistically significant difference in contamination rates was found between the two printing temperatures.
• Culture conditions did not significantly impact the microbial reduction observed.

Conclusions:

• Fused deposition modeling (FDM) demonstrates a significant capability to reduce microbial load on printed materials.
• This suggests FDM could be explored as a single-stage, point-of-care sterilization method for surgical instruments.
• Further research is required to optimize parameters and validate effectiveness against a broader range of resistant pathogens.