3D Printed Hernia Mesh with Self-Adhesive Hydrogel Coating
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Solution Overview
Problem
Current hernia meshes cause adverse reactions such as chronic pain, adhesions, and foreign body reactions due to mechanical fixation and poor biocompatibility, leading to complications and recurrence in hernia repair surgeries.
Innovation Solution
A 3D printed hernia mesh with a core-shell structure and biodegradable materials is developed, allowing for customizable pore size, tensile strength, and elasticity, using a 3D printing method that includes heating and melting steps to create a self-adhesive mesh with reduced foreign body sensation and inflammation, and surface treatment for improved bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional plastic meshes (polypropylene, polyester, ePTFE) are used for hernia repair, then the mesh provides structural strength and durability, but it causes severe adhesions, chronic pain, and foreign body reactions due to poor biocompatibility
Solution Approach 1:
The patent uses a composite structure consisting of a PLA mesh base combined with a hydrogel coating layer. The PLA provides the necessary mechanical strength and structural integrity, while the hydrogel coating (containing gelatin, hyaluronic acid, and collagen) provides excellent biocompatibility, prevents adhesions, and reduces inflammation. This composite approach allows both requirements to be satisfied simultaneously.
Solution Approach 2:
The mesh structure incorporates varying pore sizes and wall thicknesses in different regions to optimize both mechanical strength and biological functionality. The core-shell structure with different material properties in different layers allows the outer surface to be highly biocompatible while the inner structure maintains structural strength.
2Stability of the object's composition
If mechanical fixation devices (tacks, sutures, anchors) are used to secure the mesh, then the mesh remains stable during surgery, but it causes chronic pain and tissue damage due to perforating fixation
Solution Approach 1:
The patent replaces mechanical fixation devices with a self-adhesive mechanism. The hydrogel coating on the mesh surface creates strong adhesion to the surrounding tissue through biochemical bonding, eliminating the need for tacks, sutures, or anchors that cause pain and tissue damage. The adhesion is achieved through the functional groups in the hydrogel that bond with tissue proteins.
3Duration of action of stationary object
If permanent non-absorbable meshes are used, then the mesh maintains long-term structural support, but it causes ongoing foreign body reactions and requires removal if infection occurs
Solution Approach 1:
The patent employs a temporal dynamic approach where the mesh properties change over time. The PLA mesh provides structural support initially, then gradually degrades as the tissue heals and forms its own scar tissue reinforcement. The hydrogel coating degrades faster, providing immediate biocompatibility and anti-adhesion properties, then disappears as it serves its protective function. This dynamic behavior eliminates permanent foreign body reactions.
Solution Approach 2:
The patent utilizes controlled degradation parameters of biodegradable materials. The PLA mesh is designed with specific molecular weight and crystallinity to control its degradation rate, ensuring it maintains strength during the critical healing period then gradually breaks down. The hydrogel coating's degradation rate is tuned to provide protection during the inflammatory phase then dissolve without causing chronic reactions.
4Object-affected harmful factors
If bioabsorbable meshes (polyglycolic acid, lactide copolymer) are used, then the mesh reduces foreign body reactions, but it loses strength within 1 month before the hernia site has healed
Solution Approach 1:
The patent combines PLA, which has slower degradation and maintains strength longer, with a hydrogel coating that provides immediate biocompatibility. The PLA's structural integrity persists throughout the healing period while the hydrogel provides the anti-inflammatory and anti-adhesion benefits. This composite structure prevents the early strength loss experienced with pure polyglycolic acid meshes.
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 3D printed hernia mesh reduces tissue inflammatory response, promotes tissue growth, maintains strength during healing, and degrades consistently with patient recovery, minimizing complications and postoperative pain, and eliminates the need for mechanical fixation, thereby reducing recurrence rates.
Implementation Method 1
heating the filler tube to a first temperature, and maintaining for a first preset time to remove moisture contained in the first material particle; S3, continuously heating the filler tube to a second temperature, and maintaining for a second preset time to completely melt the first material particle
Implementation Method 2
continuously heating the filler tube to a second temperature, and maintaining for a second preset time to completely melt the first material particle
Data Source
AI summary
The present application relates to a hernia mesh and its preparation method. A preparation method of hernia mesh comprises selecting and adding a first material particle into a filler tube attached to a 3D printer, and making an external pressure pipe connected; heating the filler tube to a first temperature, and maintaining for a first preset time to remove moisture contained in the first material particle; continuously heating the filler tube to a second temperature, and maintaining for a second preset time to completely melt the first material particle; continuously heating filler tube to a third temperature, and using a designed hernia mesh 3D print file to prepare the hernia mesh by the 3D printer. The hernia mesh prepared has controllable pore size, biocompatibility, tensile strength, and elasticity; the preparation process is convenient and quick, reducing the cost; the patient's foreign body sensation and discomfort can be reduced.