3D Printed Polymer Stent Manufacturing via Additive Layering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current stent manufacturing methods, particularly using laser cutting technology, result in material wastage and difficulties in achieving appropriate mechanical strength, and existing biocompatible stents face issues with prolonged antiplatelet therapy and vascular irritation due to polymer use.
Innovation Solution
The method involves 3D printing using a computer-readable design and a 3D printer with a nozzle to create biocompatible stents from polymeric materials, optimizing nozzle aperture diameter and printer resolution, and using thermoplastic polymers like PLA, with support structures and controlled ink temperature for efficient layer formation and minimal material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If laser cutting technology is used to manufacture stents, then stents can be created from metallic materials, but material wastage occurs and mechanical strength is difficult to achieve
Solution Approach 1:
Instead of removing material from a solid cylinder to create a stent (subtractive manufacturing), the patent uses additive manufacturing to build the stent layer by layer from molten polymer material. This inversion of the manufacturing approach eliminates material wastage while allowing precise control over strut dimensions to achieve optimal mechanical strength.
Solution Approach 2:
The patent changes the physical state of the polymer material from solid to molten and back to solid through controlled heating and cooling during the 3D printing process. By adjusting parameters such as nozzle temperature, print speed, and layer thickness, the invention achieves precise control over the deposited material properties, ensuring optimal mechanical strength without material wastage.
2Object-affected harmful factors
If polymer materials are used for biocompatible stents, then biocompatibility is improved, but vascular irritation and need for prolonged antiplatelet therapy occur
Solution Approach 1:
The patent applies different surface qualities to different parts of the stent structure. The inner surface that contacts blood is designed with specific roughness and porosity characteristics to minimize vascular irritation, while maintaining structural integrity. This localized optimization of surface properties reduces endothelial dysfunction and inflammation while preserving biocompatibility.
3Ease of manufacture
If laser cutting is used to create stents, then stents can be manufactured, but strut dimensions are difficult to control correctly
Solution Approach 1:
The 3D printing process incorporates real-time monitoring and feedback control of the nozzle temperature, material flow rate, and layer deposition accuracy. This feedback mechanism allows continuous adjustment of printing parameters to maintain precise strut dimensions throughout the manufacturing process, ensuring consistent mechanical properties and proper stent expansion characteristics.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes material wastage, achieves optimal mechanical strength, reduces the need for prolonged antiplatelet therapy, and enhances biocompatibility by creating stents with controlled strut thickness and vascular coverage, improving stent performance and patient outcomes.
Implementation Method 1
a 3D printer comprising a nozzle; instructing the 3D printer to print the design of the stent, such that non-metallic ink is expelled from the nozzle to thereby form the stent
Implementation Method 2
The ink used to create the stent is a thermoplastic polymer
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention provides a method of manufacturing a stent (12) using a three dimensional (3D) printer. The invention also extends to 3D printed stents and second medical uses of such stents. The invention also extends to electric signals carrying computer-executable instructions adapted to cause a 3D printer to print a stent, computer-readable programs and computer-readable mediums.