Medical devices and methods for producing the same
AssigneeAdditive Device, Inc.
InventorAndrew Todd Miller
Life of this patent
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Abstract
The present disclosure relates generally to medical devices, including airway stents, and additive manufacturing (3D printing) processes for producing the same. Using certain materials and novel printing techniques, the present systems and methods can directly print nearly any size or shape medical device in a few hours. For example, in certain embodiments, the present systems and methods leverage fused deposition modeling (“FDM”) and polycarbonate urethane (“PCU”) to produce custom medical devices, including airway stents.
Claims30
A method for producing a seamless polycarbonate urethane airway stent comprising the steps of:
- heating a nozzle operatively connected to a print bed to approximately 225 degrees Celsius, the nozzle capable of moving along an x-axis, y-axis, and z-axis and comprising a diameter of approximately 0.5 millimeters;
- heating the print bed to approximately 65 degrees Celsius;
- drying polycarbonate urethane (PCU) filament via a vacuum oven at a temperature of at least 99 degrees Celsius for a minimum of 30 minutes, thereby substantially drying the PCU filament;
- feeding the substantially dry PCU filament through the nozzle, wherein the nozzle melts the substantially dry PCU filament;
- creating a first layer of the seamless polycarbonate urethane airway stent by:
- starting the nozzle at a first point on a first x-y plane and extruding melted PCU filament along a first path at a first speed, creating an outer perimeter of the first layer;
- extruding melted PCU filament along a second path, creating an inner perimeter of the first layer;
- and
- extruding melted PCU in a first rectilinear infill pattern along the first x-y plane between the inner and outer perimeters of the first layer, wherein the distance between an exterior of the outer perimeter and an interior of the inner perimeter is about 0.75 mm to 0.85 mm;
- moving the nozzle along the z-axis;
- and
- creating a second layer of the seamless polycarbonate urethane airway stent by:
- starting the nozzle at a second point on a second x-y plane and extruding melted PCU filament along a third path at a second speed approximately double the first speed, creating an outer perimeter of the second layer;
- extruding melted PCU filament along a fourth path creating an inner perimeter of the second layer;
- and
- extruding melted PCU in a second rectilinear infill pattern along the second x-y plane between the inner and outer perimeters of the second layer, wherein the first point and the second point are different points, thereby creating the seamless polycarbonate urethane airway stent, wherein the seamless polycarbonate urethane airway stent comprises a hollow interior.
A method for producing a polycarbonate urethane stent comprising the steps of:
- heating a nozzle operatively connected to a bed to approximately 225 degrees Celsius, the nozzle capable of moving along a x-axis, a y-axis, and a z-axis and comprising a diameter of approximately 0.5 millimeters;
- substantially drying polycarbonate urethane filament;
- heating the bed to approximately 65 degrees Celsius;
- feeding the substantially dry PCU filament through the nozzle, wherein the nozzle melts the substantially dry PCU filament;
- and
- extruding melted PCU filament in discrete vertical layers, wherein each discrete vertical layer is created by:
- a) extruding melted PCU filament along an outer perimeter of the medical device in an x-y plane, and b) extruding melted PCU in a rectilinear infill pattern along the x-y plane to fill-in the discrete vertical layer of the polycarbonate urethane stent from the outer perimeter to an inner perimeter, thereby creating the polycarbonate urethane stent comprising a wall thickness of 0.75 mm to 0.85 mm with a radial stiffness of between 8 to 20 N/mm tested at about 37 degrees Celsius, wherein the polycarbonate urethane stent comprises a hollow interior.
Dependencies are inferred from the claim text.