Dynamic topology optimization of 3D-Printed transtibial orthopedic implant using tunable isotropic porous metamaterials.

In this paper, we introduce the design and manufacturing process of a transtibial orthopedic implant. We used medical-grade polyurethane polymer resin to fabricate a 3D porous architected implant with tunable isotropy, employing a high-speed printing method known as Continuous Liquid Interface Production (CLIP). Our objective is to enhance the weight-bearing capabilities of the bone structures in the residual limb, thereby circumventing the traditional reliance on a natural bridge. To achieve a custom-made design, we acquire the topology and morphology of the residual limb as well as the bone structure of the tibia and fibula, utilizing computed tomography (CT) and high-resolution 3D scanning. We employed a dynamic topological optimization method, informed by gait cycle data, to effectively reduce the mass of the implant. This approach, which differs from conventional static methods, enables the quantification of variations in applied forces over time. Using the Euler-Lagrange energy approach, we propose the equations of motion for a homologous multibody model with three degrees of freedom. The versatility of the Solid Isotropic Material with Penalization (SIMP) method facilitates the integration of homogenization methods for microscale porous architectures into the optimized domain. The design of these porous architectures is based on a bias-driven tuning symmetry isotropy of a Triply Periodic Minimal Surface (Schwarz Primitive surface). The internal porosity of the structure significantly reduces weight without compromising the isotropic behavior of the implant.

Reinforcement of Alginate-Gelatin Hydrogels with Bioceramics for Biomedical Applications: A Comparative Study.

This study states the preparation of novel ink with potential use for bone and cartilage tissue restoration. 3Dprint manufacturing allows customizing prostheses and complex morphologies of any traumatism. The quest for bioinks that increase the restoration rate based on printable polymers is a need. This study is focused on main steps, the synthesis of two bioceramic materials as WO3 and Na2Ti6O13, its integration into a biopolymeric-base matrix of Alginate and Gelatin to support the particles in a complete scaffold to trigger the potential nucleation of crystals of calcium phosphates, and its comparative study with independent systems of formulations with bioceramic particles as Al2O3, TiO2, and ZrO2. FT-IR and SEM studies result in hydroxyapatite's potential nucleation, which can generate bone or cartilage tissue regeneration systems with low or null cytotoxicity. These composites were tested by cell culture techniques to assess their biocompatibility. Moreover, the reinforcement was compared individually by mechanical tests with higher results on synthesized materials Na2Ti6O13 with 35 kPa and WO3 with 63 kPa. Finally, the integration of these composite materials formulated by Alginate/Gelatin and bioceramic has been characterized as functional for further manufacturing with the aid of novel biofabrication techniques such as 3D printing.

E-Skin Development and Prototyping via Soft Tooling and Composites with Silicone Rubber and Carbon Nanotubes.

The strategy of embedding conductive materials on polymeric matrices has produced functional and wearable artificial electronic skin prototypes capable of transduction signals, such as pressure, force, humidity, or temperature. However, these prototypes are expensive and cover small areas. This study proposes a more affordable manufacturing strategy for manufacturing conductive layers with 6 × 6 matrix micropatterns of RTV-2 silicone rubber and Single-Walled Carbon Nanotubes (SWCNT). A novel mold with two cavities and two different micropatterns was designed and tested as a proof-of-concept using Low-Force Stereolithography-based additive manufacturing (AM). The effect SWCNT concentrations (3 wt.%, 4 wt.%, and 5 wt.%) on the mechanical properties were characterized by quasi-static axial deformation tests, which allowed them to stretch up to ~160%. The elastomeric soft material's hysteresis energy (Mullin's effect) was fitted using the Ogden-Roxburgh model and the Nelder-Mead algorithm. The assessment showed that the resulting multilayer material exhibits high flexibility and high conductivity (surface resistivity ~7.97 × 104 Ω/sq) and that robust soft tooling can be used for other devices.

Alginate/Gelatin Hydrogels Reinforced with TiO2 and ß-TCP Fabricated by Microextrusion-based Printing for Tissue Regeneration.

Three-dimensional (3D) printing technologies have become an attractive manufacturing process to fabricate scaffolds in tissue engineering. Recent research has focused on the fabrication of alginate complex shaped structures that closely mimic biological organs or tissues. Alginates can be effectively manufactured into porous three-dimensional networks for tissue engineering applications. However, the structure, mechanical properties, and shape fidelity of 3D-printed alginate hydrogels used for preparing tissue-engineered scaffolds is difficult to control. In this work, the use of alginate/gelatin hydrogels reinforced with TiO2 and ß-tricalcium phosphate was studied to tailor the mechanical properties of 3D-printed hydrogels. The hydrogels reinforced with TiO2 and ß-TCP showed enhanced mechanical properties up to 20 MPa of elastic modulus. Furthermore, the pores of the crosslinked printed structures were measured with an average pore size of 200 µm. Additionally, it was found that as more layers of the design were printed, there was an increase of the line width of the bottom layers due to its viscous deformation. Shrinkage of the design when the hydrogel is crosslinked and freeze dried was also measured and found to be up to 27% from the printed design. Overall, the proposed approach enabled fabrication of 3D-printed alginate scaffolds with adequate physical properties for tissue engineering applications.

Parametric Modeling of Biomimetic Cortical Bone Microstructure for Additive Manufacturing.

In this work we present a novel algorithm for generating in-silico biomimetic models of a cortical bone microstructure towards manufacturing biomimetic bone via additive manufacturing. The software provides a tool for physicians or biomedical engineers to develop models of cortical bone that include the inherent complexity of the microstructure. The correspondence of the produced virtual prototypes with natural bone tissue was assessed experimentally employing Digital Light Processing (DLP) of a thermoset polymer resin to recreate healthy and osteoporotic bone tissue microstructure. The proposed tool was successfully implemented to develop cortical bone structure based on osteon density, cement line thickness, and the Haversian and Volkmann channels to produce a user-designated bone porosity that matches within values reported from literature for these types of tissues. Characterization of the specimens using a Scanning Electron Microscopy with Focused Ion Beam (SEM/FIB) and Computer Tomography (CT) revealed that the manufacturability of intricated virtual prototype is possible for scaled-up versions of the tissue. Modeling based on the density, inclination and size range of the osteon and Haversian and Volkmann´s canals granted the development of a dynamic in-silico porosity (13.37⁻21.49%) that matches with models of healthy and osteoporotic bone. Correspondence of the designed porosity with the manufactured assessment (5.79⁻16.16%) shows that the introduced methodology is a step towards the development of more refined and lifelike porous structures such as cortical bone. Further research is required for validation of the proposed methodology model of the real bone tissue and as a patient-specific customization tool of synthetic bone.

Electrospun Polycaprolactone Fibrous Membranes Containing Ag, TiO2 and Na2Ti6O13 Particles for Potential Use in Bone Regeneration.

Biocompatible and biodegradable membrane treatments for regeneration of bone are nowadays a promising solution in the medical field. Bioresorbable polymers are extensively used in membrane elaboration, where polycaprolactone (PCL) is used as base polymer. The goal of this work was to improve electrospun membranes' biocompatibility and antibacterial properties by adding micro- and nanoparticles such as Ag, TiO2 and Na2Ti6O13. Micro/nanofiber morphologies of the obtained membranes were characterized by X-ray diffraction, Fourier-transform infrared spectroscopy, differential scanning calorimetry, scanning electron microscopy, energy-dispersive X-ray spectroscopy and a tensile test. Also, for this study optical microscopy was used to observe DAPI-stained cells. Membranes of the different systems were electrospun to an average diameter of 1.02⁻1.76 µm. To evaluate the biological properties, cell viability was studied by growing NIH/3T3 cells on the microfibers. PCL/TiO2 strength was enhanced from 0.6 MPa to 6.3 MPa in comparison with PCL without particles. Antibacterial activity was observed in PCL/TiO2 and PCL/Na2Ti6O13 electrospun membranes using Staphylococcus aureus bacteria. Bioactivity of the membranes was confirmed with simulated body fluid (SBF) treatment. From this study, the ceramic particles TiO2 and Na2Ti6O13, combined with a PCL matrix with micro/nanoparticles, enhanced cell proliferation, adhesion and antibacterial properties. The electrospun composite with Na2Ti6O13 can be considered viable for tissue regenerative processes.