Collaborative Effort to Revolutionize 3D Printing in Medical Device Manufacturing

USA: A pioneering research initiative, featuring a collaboration between The University of Texas at Austin, Georgia Institute of Technology, Penn State University, and Actuated Medical Inc., seeks to elevate the realm of medical device customization through innovative 3D printing methods. Focused on shape-adaptive medical devices, the project aims to revolutionize the production of items like noninvasive ventilation masks to provide tailored solutions for individual patients.

All-Female Team Embarks on a Five-Year Exploration

Led by Professor Carolyn Seepersad from Georgia Tech, the all-female team includes co-leaders from Penn State—Mary Frecker, Zoubeida Ounaies, and Lorraine Dowler—as well as Maureen Mulvihill, president and CEO of Actuated Medical. The five-year project, supported by a grant from the National Science Foundation’s LEAP-HI program, endeavours to refine the process of 3D printing shape-adaptive medical devices.

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The research project aims to pioneer novel techniques in 3D printing to produce customizable medical devices with an enhanced range of motion. The team envisions creating smart devices capable of changing shape after manufacturing, providing an optimized fit for various patients. This transformative approach involves the integration of magnetic particles within the 3D-printed material, allowing for shape adaptation post-production.

Manufacturing Breakthroughs with Reactive Extrusion 3D Printing

The team employs a unique 3D printing technology, known as reactive extrusion 3D printing, using in-house-built printers similar to desktop extrusion printers. By incorporating robotic arms in the fabrication process, the team experiments with thermoset polymers, differentiating from traditional thermoplastics. The process involves reactive extrusion, where multi-part thermoset resin is mixed and deposited through a motion-controlled extrusion nozzle.

Designing 3D-printed shape-adaptive medical devices presents several challenges, especially for noninvasive ventilation masks. The team, led by Seepersad and Frecker, utilizes machine learning models to map interactions within the dataset, guiding the design process. The ultimate goal is to create masks that can adjust to different patients’ unique anatomy, redistributing pressure points for increased comfort and preventing material waste.

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Materials Science: A Critical Component for Success

Zoubeida Ounaies, leading the material science segment, explores the properties and behaviour of feedstock materials. The project delves into the addition of viscosity-enhancing agents, investigating fillers like magnetic and conductive particles. The team aims to find the right balance to achieve not only shape change but also strength, durability, and flexibility while ensuring optimal printability.

Social scientist Lorraine Dowler adds a unique layer to the project by studying the interactions, collaborations, and thoughts of the all-female team. Dowler’s role is to understand and promote diversity in STEM fields, observing how the team dynamics contribute to the overall success of the project.

As the project continues its exploration, the convergence of innovation, material science, design, and social science promises groundbreaking advancements in 3D printing for medical device customization.