3D printed element for a bioprocessing flow path and method of forming

3D printing with polymer-based powders and advanced surface finishing techniques produce bioprocessing elements with smooth, cleanable surfaces, effectively addressing the challenges of bioaccumulation and contamination in bioprocessing systems.

WO2026109472A1PCT designated stage Publication Date: 2026-05-28CYTIVA SWEDEN AB
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Patent Information

Application Number
PCT/EP2025/083308
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2024-11-19
Filing Date
2025-11-17
Publication Date
2026-05-28

AI Technical Summary

Technical Problem

Bioprocessing systems face challenges with metal components that are expensive, complex to manufacture, and prone to bioaccumulation and contamination due to intricate geometries and surface irregularities, which are difficult to clean and sanitize, especially in internal geometries, necessitating alternative technologies that are cost-effective and improve cleanability and sterilization.

Method used

A method involving 3D printing with polymer-based powders followed by sequential surface finishing processes, including vibratory finishing and chemical treatments, to create elements with smooth, wettable surfaces that meet stringent sanitization requirements, such as removing at least 95% of residual powder particles and achieving an arithmetic average roughness (Ra) of less than 4 μm.

Benefits of technology

The method ensures effective sanitization and reduces the risk of contamination by achieving smooth, cleanable surfaces that meet bioprocessing standards, addressing the challenges of bioaccumulation and surface imperfections in bioprocessing systems.

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Abstract

A method for forming a 3D printed element (100) is disclosed, which is configured to form part of a flow path of a bioprocessing system. The 3D printed element (100) comprises a wettable surface (110) configured to be exposed to a liquid feed transported in the flow path (F). The method comprises sequentially depositing a printing medium to form the 3D printed element (100), the printing medium being a polymer-based powder, removing excess powder from the element (100) by means of a depowdering process, removing, by means of a first surface finishing process, residual powder particles remaining on the wettable surface (110) after the depowdering process, and smoothening the wettable surface (110) by means of a second surface finishing process, wherein the second surface finishing process comprising a chemical treatment.
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Citation Information

Patent Citations

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  • Device and method for surface smoothing additively manufactured shaped parts consisting of plastic

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  • Heat treatment of 3D printed parts

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