Additively Manufactured Mesh Materials for Wearable Devices
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Solution Overview
Problem
Conventional soft tissue devices, such as ankle braces, are often cumbersome and fail to provide localized control over mechanical properties, leading to mechanical mismatch with the wearer's tissues, which can result in complications like muscle atrophy and excessive force on other joints, and existing additive manufacturing techniques produce weak and brittle fabrics that are difficult to customize for individual anatomy.
Innovation Solution
The development of a direct-write additive manufacturing process that allows for explicit control of toolpath and hardware to pattern continuous fibers, enabling localized control over fabric geometry, topology, and composition, resulting in mesh materials with controllable local stiffness and anisotropic mechanical response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional additive manufacturing techniques are used to produce soft tissue devices, then manufacturing capability is achieved, but the resulting fabrics are weak and brittle
Solution Approach 1:
The patent employs composite materials by combining continuous fibers with a matrix material to create a hybrid structure. The continuous fibers provide tensile strength and structural integrity, while the matrix material binds the fibers together and distributes loads. This composite approach resolves the contradiction by enabling manufacturable soft tissue devices that achieve both fabrication capability and enhanced fabric strength through synergistic material combination.
Solution Approach 2:
The patent implements local quality by varying the fiber orientation, density, and material composition at different locations within the device. This allows regions of high stress to have higher fiber concentration and strength, while less critical areas have lower material density. This localized optimization enables the device to achieve sufficient overall strength while maintaining manufacturability through region-specific material properties.
2Reliability
If conventional braces are used to immobilize joints, then joint stability is improved, but muscle atrophy and excessive force on other joints occur
Solution Approach 1:
The patent applies local quality by creating spatially varying mechanical properties within the device. Different regions have different stiffness characteristics, allowing the device to provide rigid support where joint stability is critical while maintaining flexibility in regions that require muscle activation and movement. This gradient of mechanical properties enables the device to stabilize the joint without causing complete immobilization and subsequent muscle atrophy.
Solution Approach 2:
The patent incorporates dynamic characteristics by designing the device to adapt its mechanical response based on loading conditions and physiological movements. The continuous fiber reinforcement and mesh structure allow the device to stiffen under high loads while remaining compliant during normal physiological ranges of motion. This dynamic behavior provides joint stability when needed while permitting controlled movement to prevent muscle atrophy and reduce excessive forces on other joints.
3Adaptability or versatility
If customized devices are manufactured for individual anatomy, then device fit and mechanical matching are improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs segmentation by dividing the device into modular components with standardized interfaces. The continuous fiber reinforcement and mesh structure can be manufactured as separate modules that are subsequently assembled. This segmentation allows customization of individual modules to match patient anatomy while using standardized manufacturing processes for each module, thereby reducing overall manufacturing complexity compared to fully custom monolithic devices.
Solution Approach 2:
The patent applies universality by designing a platform architecture where certain components and manufacturing parameters can be standardized across different patient-specific devices. The continuous fiber reinforcement pattern and mesh structure serve universal functions of providing tensile strength and structural support, while only the geometric parameters and material distributions need customization. This multi-functional approach enables customization for individual anatomy while maintaining relatively simple and scalable manufacturing processes.
Data Source
AI summary
Wearable and implantable devices that are used to support human anatomy and are formed using additive manufacturing are provided. Systems and methods for performing additive manufacturing allow for the formulation of a mesh material that has localized stiffness and slack in regions to best serve the needs of the patient. For example, regions of the mesh material can be designed to rigidly support portions of human anatomy, such as injured tissue, while regions of the mesh material adjacent to the injured tissue can be designed to closely mimic movement of the relevant human anatomy. For example, the mesh material can be formed in a manner such that it does not fold in those regions, and therefore is not obtrusive. The present disclosure allows for control of toolpaths when printing fibers used to form the devices. Other devices, as well as systems and methods for creating the same, are also provided.