Rotating Print Surface for Hollow 3D Implants
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Solution Overview
Problem
Traditional 3D printing methods are unable to effectively manufacture hollow, strong, flexible, and biocompatible implantable medical devices such as mesh bags with hollow centers, due to limitations in creating structures that are not stratified and lack the necessary strength and flexibility.
Innovation Solution
A 3D printing device with a rotatable printing surface that allows for continuous extrusion, enabling the creation of hollow structures with a meshed design that are strong, flexible, and biocompatible, by rotating the printing surface in alternating directions and using a print head to apply material in a wave-like pattern, allowing for the formation of interconnected strands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional layered 3D printing is used to create hollow structures, then the manufacturing process is simple, but the resulting structures lack strength and flexibility
Solution Approach 1:
The patent introduces a rotatable printing surface that can rotate in alternating directions during the printing process. This dynamic element allows the continuous extrusion of material to form three-dimensional hollow structures with interconnected strands, transforming the static layered printing process into a dynamic continuous process that produces stronger, more flexible structures
Solution Approach 2:
The patent implements continuous extrusion of material without layer-by-layer deposition. The material is continuously extruded from the print head onto the rotating print surface, forming uninterrupted interconnected strands that create hollow structures with superior strength and flexibility compared to traditional layered approaches
2Ease of manufacture
If traditional layered 3D printing is used, then material deposition is straightforward, but hollow structures cannot be effectively manufactured
Solution Approach 1:
The rotatable print surface rotates in alternating directions while material is continuously extruded, enabling the formation of complex hollow three-dimensional structures. This dynamic rotation allows the print head to deposit material in patterns that create enclosed hollow regions, achieving manufacturing precision for hollow structures while maintaining ease of manufacture through continuous extrusion
Solution Approach 2:
The patent transitions from two-dimensional layered deposition to three-dimensional continuous extrusion by introducing the rotation dimension. The print surface rotates while material is extruded, adding a temporal and spatial dimension to the manufacturing process that enables hollow structure formation without compromising ease of manufacture
3Adaptability or versatility
If monolithic or particulated bone grafts are used, then implantation is simple, but customization ability is limited
Solution Approach 1:
The continuous extrusion process allows different regions of the implant to have different material properties, densities, and structural characteristics. The rotatable print surface enables localized variation in strand thickness, spacing, and interconnection patterns, providing customization ability while maintaining a relatively simple overall implant structure suitable for straightforward implantation
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 production of hollow structures like mesh bags that are suitable for implantable medical devices, providing enhanced strength, flexibility, and biocompatibility, with reduced waste and improved customization options.
Implementation Method 1
a print head disposed adjacent to and substantially transverse to the print surface, the print head configured to apply material used to make the implant on at least a portion of the print surface
Implementation Method 2
a print surface rotatable in a clockwise and counterclockwise direction about an axis of rotation
Implementation Method 3
a base disposed adjacent to the print head and contacting the print surface, the base configured to be movable in forward, backward and lateral directions relative to the print head to make the implant having the hollow region
Data Source
AI summary
A device is provided for making an implant having a hollow region, the device comprising a print surface rotatable in a clockwise and counterclockwise direction about an axis of rotation; a print head disposed adjacent to and substantially transverse to the print surface, the print head configured to apply material used to make the implant on at least a portion of the print surface or heat material disposed on at least a portion of the print surface used to make the implant; and a base disposed adjacent to the print head and contacting the print surface, the base configured to be movable in forward, backward and lateral directions relative to the print head to make the implant having the hollow region. Methods of using the device and are also disclosed.