Biocompatible 3D Object Coating via Multi-Axis Deposition
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Solution Overview
Problem
Existing techniques are inadequate for producing biocompatible three-dimensional objects with complex shapes, such as concave or convex heart patches, ellipsoidal cardiac chambers, and patches for calcaneal ulcers, due to limitations in achieving high dimensional precision and accurate modeling of surfaces with varying radii of curvature.
Innovation Solution
An apparatus with a delivery unit and handling unit allowing movement in at least 3 degrees of freedom, combined with a suction and blowing unit, enables precise deposition and removal of biocompatible fluid substances on a support body, allowing for the creation of complex three-dimensional objects with surfaces of varying curvature, and includes optional features like anthropomorphic robots and counter-molds for enhanced precision and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional spraying techniques are used with a rotating cylindrical support element, then membranes with simple axisymmetric shape can be produced, but complex three-dimensional objects with varying radii of curvature cannot be manufactured
Solution Approach 1:
The invention transforms the static rotating cylindrical support into a dynamic system where both the support body and delivery unit can move relative to each other along multiple degrees of freedom. This dynamic positioning system allows the delivery unit to approach the support body from different angles and distances, enabling precise deposition of coating material on complex three-dimensional surfaces with varying curvatures while maintaining consistent layer thickness and high dimensional accuracy.
2Adaptability or versatility
If the support body rotates about a fixed axis while the sprayer translates along a parallel axis, then axisymmetric membranes can be produced, but objects with non-axisymmetric or complex geometries cannot be created
Solution Approach 1:
The invention creates a universal manufacturing system where the delivery unit and support body can perform multiple functions through coordinated movement along several degrees of freedom. This multi-functional positioning system can accommodate various complex geometries including concave and convex surfaces, ellipsoidal shapes, and non-axisymmetric forms, making the apparatus adaptable to produce diverse three-dimensional objects beyond simple axisymmetric membranes.
3Manufacturing precision
If multiple sprayers are used to deposit polymeric solution and non-solvent simultaneously or alternately, then coating can be formed, but precise control of layer thickness on complex surfaces is difficult
Solution Approach 1:
The invention implements a feedback-controlled positioning system where the relative movement between the delivery unit and support body is precisely controlled along multiple degrees of freedom. This feedback mechanism maintains optimal distance and orientation between the delivery unit and the support body surface, ensuring uniform coating layer thickness even on complex three-dimensional surfaces with varying curvatures, while coordinating multiple delivery units to deposit polymeric solution and non-solvent in precise sequences.
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
The apparatus achieves high precision in producing biocompatible three-dimensional objects with complex shapes, ensuring accurate replication of pre-designed models and improved mechanical features through controlled layer thickness and surface finishing, suitable for anatomical prostheses with varying geometries.
Implementation Method 1
a suction and blowing unit is also provided configured to provide a suction and blowing current arranged to remove from the support body any surplus particles of the biocompatible fluid substance supplied by the or each delivery unit
Implementation Method 2
at least one delivery unit arranged to deliver at least one biocompatible fluid substance towards a support body, also called core, that has a matrix surface, to obtain a coating layer of a predetermined thickness
Data Source
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AI summary
An apparatus for making a biocompatible three-dimensional object including at least one delivery unit arranged to deliver at least one biocompatible fluid substance towards a 3D mold having a matrix surface to obtain a coating layer of a predetermined thickness configured for coating the matrix surface. The three-dimensional object may be a heart valve. Furthermore, a handling unit is provided arranged to provide a relative movement according to at least 3 degrees of freedom between the 3D mold and each delivery unit. The 3D mold is arranged to be coated by the delivered biocompatible fluid substance, in order to obtain a three-dimensional object having an object surface copying the matrix surface of the support body.