# US 11,993,001 B2 · Additive manufacturing methods utilizing a robotic arm

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- Number: US 11,993,001 B2
- Document ID: US11993001B2
- Status: Granted
- Kind: B2
- Application number: 18/144,646
- Filed: 2023-05-08
- Published: 2023-11-09
- Granted: 2024-05-28
- Earliest claimed: 2019-04-04
- Assignees: Ohio State Innovation Foundation
- Applicants: Ohio State Innovation Foundation
- Inventors: David J. Hoelzle; Desmond M. D′Souza; Andrej Simeunovic; Ali Asghari Adib
- Web page: https://patentgrep.com/patent/US11993001B2

## CPC

- B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM]
- A61K 35/12: Materials from mammals; Compositions comprising non-specified tissues or cells; Compositions comprising non-embryonic stem cells; Genetically modified cells (vaccines or medicinal preparations containing antigens or antibodies A61K39/00)
- B22F 10/20: Direct sintering or melting
- B29C 64/227: Driving means
- B29C 64/30: Auxiliary operations or equipment
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 70/00: Materials specially adapted for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C12N 5/0062: {General methods for three-dimensional culture}
- B22F 12/90: Means for process control, e.g. cameras or sensors
- B29C 64/209: Heads; Nozzles
- B29C 64/232: for motion along the axis orthogonal to the plane of a layer
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B29K 2105/0061: {Gel or sol}
- B29L 2031/753: {Medical equipment; Accessories therefor (bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008)}
- Y02P 10/25: Process efficiency
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- A61K: PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES (devices or methods specially adapted for bringing pharmaceutical products into particular physical or administering forms A61J3/00; chemical aspects of, or use of materials for deodorisation of air, for disinfection or sterilisation, or for bandages, dressings, absorbent pads or surgical articles A61L; soap compositions C11D)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C12N: MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA (microbiological testing media C12Q1/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

The present disclosure provides methods for freeform extrusion-based additive manufacturing via a robotic arm. In specific aspects, methods are particularly provided for minimally invasive, intracorporeal three-dimensional printing of biocompatible materials. An end effector of a robotic arm includes a sharp member and a reservoir filled with a printing material. The provided method may include piercing a substrate with the sharp member. A bulb or micro-bolus of material may be extruded beneath the substrate surface to act as an anchor. The end effector may be manipulated to extrude biomaterial along a printing path. Periodically along the printing path, the sharp member is used to pierce the substrate surface create additional respective anchors. In some instances, the method may terminate after extruding material to form a single layer construct. In other instances, the method includes forming one or more layers on top of the initial base layer anchored to the substrate.

## Claims

### Claim 1

A method for additive manufacturing using an end effector of an actuator joint mechanically linked to a robotic arm, the method comprising:
extruding a first bulb of printing material beneath a printing surface at a first anchor point;
solidifying the first bulb of printing material;
extruding printing material along a first printing path on the printing surface; and
solidifying the printing material along the first printing path,
wherein the first bulb of printing material is continuously connected with the printing material extruded along the first printing path on the printing surface through an opening on the printing surface,
wherein the first bulb of printing material is larger than the opening on the first printing.

### Claim 2 (depends on 1)

The method of claim 1, further comprising piercing the printing surface at the first anchor point with the end effector.

### Claim 3 (depends on 1)

The method of claim 1, further comprising:
extruding a second bulb of printing material beneath the printing surface at the second anchor point;
solidifying the second bulb of printing material;
extruding printing material along a second printing path on the printing surface;
solidifying the printing material along the second printing path.

### Claim 4 (depends on 1)

The method of claim 1, wherein extruding respective printing material and solidifying the respective printing material are simultaneous.

### Claim 5 (depends on 1)

The method of claim 1, wherein the printing material partially solidifies as it is extruded.

### Claim 6 (depends on 1)

The method of claim 1, wherein solidifying the printing material includes exposing the printing material to light.

### Claim 7 (depends on 6)

The method of claim 6, wherein the printing surface is continuously exposed to the light while the printing material is extruded.

### Claim 8 (depends on 6)

The method of claim 6, wherein the light has a wavelength in the visible spectrum.

### Claim 9 (depends on 8)

The method of claim 8, wherein the light has a wavelength between 400 nm and 495 nm.

### Claim 10 (depends on 1)

The method of claim 1, wherein the printing surface is human or animal tissue.

### Claim 11 (depends on 1)

The method of claim 1, wherein the printing surface is intracorporeal.

### Claim 12 (depends on 1)

The method of claim 1, wherein the printing material comprises at least one of a gel, a hydrogel, a paste, and a slurry.

### Claim 13 (depends on 1)

The method of claim 1, wherein the printing material comprises a gelatin methacryloyl blend.

### Claim 14 (depends on 13)

The method of claim 13, wherein the gelatin methacryloyl blend comprises 7% gelatin methacryloyl, 3% laponite, and 3% methylcellulose.

### Claim 15

A method for additive manufacturing using an end effector of an actuator joint mechanically linked to a robotic arm, the method comprising:
extruding printing material along a first printing path on a printing surface to create a first material layer, the first printing path including a plurality of anchor points, wherein creating the first material layer includes:
extruding a respective bulb of printing material beneath a printing surface at each respective anchor point of the plurality of anchor points, and
solidifying each of the respective bulbs of printing material;
solidifying the first material layer;
extruding printing material along a second printing path on the first material layer to create a second material layer;
solidifying the second material layer,
wherein the respective bulb of printing material is continuously connected with the printing material extruded along the first printing path on the printing surface through an opening on the printing surface,
wherein the respective bulb of printing material is larger than the opening on the first printing.

### Claim 16 (depends on 15)

The method of claim 15, further comprising piercing the printing surface at each respective anchor point of the plurality of anchor points with the end effector.

### Claim 17 (depends on 15)

The method of claim 15, wherein the first material layer includes a material different than the second material layer.

### Claim 18 (depends on 15)

The method of claim 15, wherein the first material layer and the second material layer are in a mesh shape.

### Claim 19 (depends on 15)

The method of claim 15, wherein the printing material comprises at least one of a gel, a hydrogel, a paste, a paste, and a slurry.

### Claim 20 (depends on 15)

The method of claim 15, wherein the printing material comprises a gelatin methacryloyl blend.