Hierarchical Photostructured Composite Scaffolds for Nanoscale Precision

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Solution Overview

Problem

Current technologies cannot produce scaffolds with sizes in the centimeter range having nanometer-scale resolution and three-dimensional structurability while maintaining macroscale structure integrity, and simultaneously increasing surface roughness and contact area.

Innovation Solution

A composite of photostructured matrix material and nanoparticles is developed, where the refractive indices of the matrix and nanoparticles are matched, allowing for hierarchical structuring with precise control of surface roughness and nanoparticle incorporation, enabling the creation of scaffolds with high accuracy and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If nanoparticles are incorporated into the scaffold to increase surface roughness and contact area, then the surface area and cell interaction are improved, but the manufacturing precision and structural integrity at macroscale are compromised

Engineering Contradiction:

Improvesurface areaVSAvoidnanometer-scale resolution

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The scaffold is segmented into hierarchical levels: macroscale structural units (10-100 mm) for overall shape, microscale features (100 nm-1000 μm) for surface roughness, and nanoparticle scale (10-1000 nm) for contact area enhancement. This segmentation allows each level to be optimized independently while maintaining overall integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite materials consisting of a photostructurable matrix combined with nanoparticles having matched refractive indices. This composite approach enables simultaneous achievement of nanometer-scale precision in structuring and high surface area through nanoparticle incorporation, resolving the contradiction between manufacturing precision and surface area enhancement.

Inventive Principle:

Principle #40Composite materials

2Measurement precision

If the refractive index difference between matrix and nanoparticles is large, then the contrast for imaging is improved, but the photostructuring precision and structural accuracy deteriorate

Engineering Contradiction:

Improveimaging contrastVSAvoidphotostructuring accuracy

Core Design Contradiction:

Measurement precisionVSManufacturing precision

Solution Approach 1:

The refractive index parameter is carefully selected and matched between matrix and nanoparticles to be within 0.5 of each other. This parameter optimization ensures that photostructuring can achieve nanometer-scale precision while still allowing for adequate imaging contrast through other means such as staining or fluorescence labeling.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If 3D printing or lithography is used to create macroscale structures, then the three-dimensional structurability is improved, but the nanometer-scale resolution and surface roughness control are lost

Engineering Contradiction:

Improvethree-dimensional structurabilityVSAvoidnanometer-scale resolution

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The invention adds a temporal dimension to the manufacturing process by using sequential photostructuring steps. First, macroscale 3D structures are created using low-resolution photostructuring, then subsequent high-resolution photostructuring passes add nanometer-scale features and surface roughness. This multi-stage approach in the time dimension enables both macroscale versatility and nanoscale precision.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 allows for the production of scaffolds with enhanced surface area and stability, enabling precise control of cell behavior and drug release, suitable for medical applications such as implants and drug delivery systems, while maintaining biocompatibility and sterilizability.

Implementation Method 1

a composite, obtainable by photostructuring a photostructurable matrix material in a composite batch containing said photostructurable matrix material and nanoparticles to form a structured matrix having nanoparticles contained therein

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11578305B2Structured composite of matrix material and nanoparticles

Publication Date: 2023.02.14 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

AI summary

The present invention provides a composite which can be produced by photostructuring a photostructurable matrix material in a composite formulation to form a structured matrix with nanoparticles, where the refractive index of the composite with nanoparticles differs from the refractive index of the composite without nanoparticles at one wavelength, selected from the range from 150 nm to 2000 nm by less than 0.5, said composite being hierarchically structured and comprising at least one structural unit (I) of a selected thickness (i) and structural units (II) branching from said structural unit (I) of a selected thickness (ii), wherein the thickness (ii) at the branch-off points is at most half the thickness (i). In addition, the present invention provides an improved process for the preparation of a composite comprising photostructured matrix material and nanoparticles contained therein and the use of the composite.