An Investigation into Patient-Specific 3D Printed Titanium Stents and the use of Etching to Overcome Selective Laser Melting Design Constraints

Abstract

Abstract There is currently a clear clinical need in the area of stenting for paediatric patients, whereby currently commercially available adult stents are often required to be used off-label for paediatric patients resulting in less than optimal outcomes. The increasingly widespread use of CT and/or MR imaging for pre-surgical assessment, and the emergence of additive manufacturing processes such as 3D printing, could enable bespoke devices to be produced efficiently and cost-effectively. However, 3D printed metallic stents need to be self-supporting leading to limitations in the design of stents available through additive manufacturing. In this study we investigate the use of etching to overcome these design constraints and improve stent surface finish. Furthermore, using a combination of experimental bench testing and finite element methods we investigate how etching influences stent performance and using an inverse finite element approach the material properties of the printed and etched stents were calibrated and compared. Finally, using patient-specific finite element models the stent performance was tested to assess patient outcomes. Within this study, etching is confirmed as a means to create open-cell stent designs whilst conforming to additive manufacturing ‘rules’ and concomitantly improving stent surface finish. Additionally, the feasibility of using an in-vivo imaging to product development pipeline is demonstrated that enables patient-specific stents to be produced for varying anatomies to achieve optimum device performance. Figure 1. Graphical abstract.