Shape memory polymer-based devices and methods of use in treating intracorporeal defects

A method of treating a specific intracorporeal defect in a subject, the method comprising the steps of:

• (1) exposing the subject to computed tomography (CT) imaging of the specific intracorporeal defect to obtain a specific three-dimensional (3D) geometry unique to the intracorporeal defect;
• (2) 3D-printing a shape memory polymer (SMP) device from an SMP foam material, wherein the SMP device has a permanent shape, a temporary shape, and a glass transition temperature, wherein the SMP device when in the permanent shape has a 3D geometry unique to the intracorporeal defect such that the permanent shape of the SMP device will substantially conform to and substantially occlude the intracorporeal defect when the SMP device is deployed into the specific intracorporeal defect at a temperature above the glass transition temperature of the SMP device, wherein the SMP foam material comprises Hexamethylene diisocyanate (HDI), N,N,N0,N0-tetrakis (hydroxypropyl)ethylenediamine (HPED), and Triethanolamine (TEA) in a HDI:HPED:TEA molar ratio of 1:0.05:0.6, and wherein at least one of a pore size, density, porosity, and compression capability of the implant is controlled in the printing step to optimize intracorporeal defect space filling and occlusion;
• (3) compressing the SMP device into a catheter, whereby the SMP device assumes its temporary shape, and wherein at least a portion of the catheter comprises a heating element;
• (4) inserting the catheter containing the compressed SMP device into the subject to an area containing the specific intracorporeal defect;
• and
• (5) deploying the SMP device from the catheter into the specific intracorporeal defect while activating the heating element of the catheter, wherein the SMP device is raised above its glass transition temperature during deployment, thereby causing the SMP device to return to its permanent shape and substantially conform to and substantially occlude the intracorporeal defect.