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Ahmad Nabeel - 3D Printing Technology in Nanomedicine

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Book:
3D Printing Technology in Nanomedicine
Author:
Ahmad Nabeel / Gopinath P / Dutta Rajiv / P Gopinath / Rajiv Dutta
Publisher:
Elsevier
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2019
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Chapter 1

3D Printing in Medicine

Current Challenges and Potential Applications

Ashish, M.TECH , Nabeel Ahmad, PhD , P. Gopinath, PhD , and Alexandr Vinogradov, PHD

Abstract

Since its introduction in the 1980s, the three-dimensional (3D) printing technology has evolved to revolutionize both scientific community and academician. The wide range of currently available manufacturing technologies provides a versatile platform for converting a prototype into a physical model. Importance of 3D printing is not only restricted to industrial area but the impact of 3D printing is also expanding in medical field in a wide range of applications including fabrication of patient-specific complex medical and anatomical structures, customized medical prostheses, implants and surgical tools, tissue and organ printing, 3D printed in vitro tissue models, drug screening purposes, advancement of physicians, and patient education. Despite significant and exciting improvements, there are many substantial challenges and barriers to the progression of 3D printing. In this chapter, we encompass the process of 3D printing, historical perspective, types of 3D printing technologies, their applications in medicine, and finally discuss various challenges to the progression of 3D printing in medicine. In the upcoming years, we believe that integration of researchers from different fields will address the challenges and barriers of 3D printing to transform the field of medicine.

Keywords

3D printing; Additive manufacturing; Organ printing; Tissue models

Introduction to Three-Dimensional Printing

The three-dimensional (3D) printing is a rapidly evolving revolutionary technology that is getting substantial interest from both scientific community and academician with users from various domains such as automotive, product designer, aerospace, engineers, consumer goods industry, architecture, military, chemical industry, food industry, fashion industry, and medical field.

Process of 3D Printing

First by using the digital design software (Autocad, Autodesk, Creo parametric, Onshape, Mimics, 3Matic, Solidworks, and Google SketchUp), 3D digital scanners, or phone-based applications, digital virtual 3D design of an object is created.

Specialized slicer software present in the 3D printer converts the .STL file into G file by slicing the design into a series of the 2D horizontal cross-section (generally in the range of 25100 m), and then the base of the 3D object is created by moving the print head in the x-y direction. Subsequently, the complete three-dimensional (3D) objects are created by repetitively moving the print head in the z -direction and depositing the desired material into layers sequentially..

Historical Perspective

In early 1980s Charles Hull was working on the development of plastic devices utilizing photopolymers but the limitations of existing technology (lengthy procedures, less accuracy) motivated him to improve the technology of prototype development. In 1984 Hull invented apparatus for a new layer-by-layer printing technology named as stereolithography. Later in 1986 Hull also founded the company 3D systems and provided the term .STL that was compatible with the existing CAD software to design the 3D object. In 1987, SLA-1 3D printer was introduced. In 1988 the company came up with the first commercially available 3D printer (SLA-250).).

Fig 12 A Major events and developments in the evolution of both 3D printing - photo 1

Fig 12 A Major events and developments in the evolution of both 3D printing - photo 2

Fig. 1.2 (A) Major events and developments in the evolution of both 3D printing and 3D printing in medicine. (B) ISI web of science data obtained in May 2016 indicating the number of articles published in 3D printing and 3D printing in biomedicine in last 10 years (R: Rate of research articles published about 3D printing to research articles published about 3D printing in medicine).
Reprinted with permission from reference Zhao H, Yang F, Fu J, et al. Printing@ clinic: from medical models to organ implants. ACS Biomater Sci Eng. 2017;3:30833097. Copyright 2017 American chemical society.

Types of 3D Printing Technologies

There are varieties of 3D printing technologies ranging from well-established methods, which have been employed in industrial settings for years, to more recent techniques under development in research laboratories that are used for more specific applications. American Society for Testing and Materials (ASTM) Committee F42 on Additive Manufacturing Technologies have grouped these technologies into seven main categories according to the methods of adding material and working principle to produce the desired 3D object ( However, the other two technologies, sheet lamination and directed energy deposition, have limited medical applications.

Vat Photopolymerization

Photopolymerization, that is, light-induced polymerization, is a form of 3D printing where materials (photopolymers, radiation-curable resins, and liquid) collected in a vat are successively cured into layers one layer at a time by irradiating with a light source thereby providing a 2D patterned layer. This involves techniques such as stereolithography (SLA), digital light processing (DLP), and continuous direct light processing (CDLP). Among these, SLA was the first 3D printing technology invented in 1986 by Chuck Hull. In1994 SLA was first utilized in medicine as a surgical tool for alloplastic implant surgery.). In bath configuration, polymerization of the topmost layer of the photoactive resin occurs by moving the light source line by line until the complete layer is being cured. Following the curing of the first layer, the substrate or stage is translated downwards to polymerize the subsequent layers in a bottom-up manner thereby printing the complete 3D structure. In this configuration, the thickness of the cured layer (C D ) depends on various factors such as intensity of light source, scanning speed, depth of focus, and period of exposure and can be described by the following equation:

CD=DPln(E/EC)

3D Printing Technology in Nanomedicine - image 3

(1.1)

where D P is the depth of light penetration, EC is the critical energy of resin, and E is the energy of the light source ( The printing performance of bath configuration depends on various factors such as light source parameters (power, speed, and depth of focus), resin parameters (viscosity, leveling of resin, and chemical composition), and printing procedure (speed, orientation, and layer thickness).

Table 1.1

Types of 3D Printing Technologies	Examples of Commonly Used Materials	Accuracy	Cost	Examples
Vat photopolymerization	Photopolymer, acrylic, and epoxy-based polymers, infused polymers	+++	$$	SLA, DLP, CDLP, Bioplotters
Powder bed fusion	Metals, plastics, ceramics, Polymers including Polycaprolactone (PCL), Hydroxyapatite (HA)	++	$$$	SLS, SLM, EBM
Binder jetting	Gypsum, Acrylates HA/PLA, HA/PCL, and bioactive glass (6P53 B)/PCL	+	$

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