3D Printing Tissue Constructs Using Phase-Changed Support
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Solution Overview
Problem
Current 3D printing techniques for tissue engineering are limited by the complexity and time required to fabricate scaffolds with intricate geometries, such as cylindrical, toroidal, and spherical shapes, and often involve the use of specialized equipment and tedious procedures, with the need for support materials that are later discarded.
Innovation Solution
A method and apparatus for creating three-dimensional tissue constructs using yield stress materials that allow for high-speed and high-precision printing by injecting biomaterials or biomaterials and cells into a temporarily phase-changed material, which acts as both the printing medium and support, eliminating the need for separate support structures and reducing manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional 3D printing techniques are used to fabricate scaffolds with intricate geometries, then the scaffolds can be created with complex shapes, but the fabrication process becomes time-consuming and requires specialized equipment
Solution Approach 1:
The patent changes the physical state of the support material by applying focused energy (thermal, acoustic, or electromagnetic) to temporarily alter its properties, enabling rapid deposition without requiring specialized equipment. This parameter change allows the material to transition between solid-like and fluid-like states, facilitating complex geometry fabrication with reduced fabrication time
Solution Approach 2:
The invention utilizes phase transitions of the support material to enable rapid fabrication. The focused energy source induces temporary phase changes in the support material, allowing it to be deposited in a fluid state and then rapidly solidify, eliminating the need for layer-by-layer solid support printing and significantly reducing fabrication time while maintaining complex geometries
2Ease of manufacture
If conventional 3D printing techniques are used, then scaffolds can be fabricated, but support materials must be printed simultaneously and later discarded, increasing material waste
Solution Approach 1:
The patent extracts the support function from the printed structure itself by using a separate deposable support material that is temporarily phase-changed during printing. This extracted support material can be easily removed after printing, eliminating the need to print and discard solid support structures and significantly reducing material waste
Solution Approach 2:
The invention introduces an intermediary support material that serves as a temporary medium during the printing process. This intermediary material is deposited in a phase-changed state, allows the biomaterial to be printed, and then can be easily removed, facilitating the manufacturing process while minimizing waste compared to conventional methods where support material is permanently incorporated
3Manufacturing precision
If conventional 3D printing techniques are used, then tissue constructs can be created, but the process lacks high-speed and high-precision capabilities
Solution Approach 1:
The patent replaces mechanical layer-by-layer deposition systems with a focused energy-based phase change system. By using thermal, acoustic, or electromagnetic energy to control material deposition and phase transitions, the system achieves both high precision (through focused energy delivery) and high speed (through rapid phase changes), eliminating the speed-precision trade-off inherent in conventional mechanical 3D printing
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
Enables the rapid and precise creation of tissue constructs with features smaller than 10 micrometers, allowing for accurate tissue replacement and repair, including complex geometries, with improved efficiency and reduced material waste, facilitating on-demand production of biocompatible tissues for wound repair and tissue cavity filling.
Implementation Method 1
a focused energy source that causes a phase change in a region of the first material by applying focused energy to that region
Data Source
AI summary
A method or apparatus for creating a three-dimensional tissue construct of a desired shape for repair or replacement of a portion of an organism. The method may comprise injecting at least one biomaterial in a three-dimensional pattern into a first material such that the at least one biomaterial is held in the desired shape of the tissue construct by the first material. The apparatus may comprise an injector configured to inject at least one biomaterial in a three-dimensional pattern into a first material such that the at least one biomaterial is held in the desired shape of the tissue construct by the first material. The first material may comprise a yield stress material, which may be a material exhibiting Herschel-Bulkley behavior. The tissue construct may have a smallest feature size of ten micrometers or less.