Systems, devices, and methods for deposition-based three-dimensional printing

• US 10,696,034 B2
• Filed: 12/12/2016
• Issued: 06/30/2020
• Est. Priority Date: 12/11/2015
• Status: Active Grant

• Current Assignee: Massachusetts Institute of Technology
• Original Assignee: Massachusetts Institute of Technology
• Inventors: Pattinson, Sebastian William, Hart, Anastasios John
• Primary Examiner(s): Khare, Atul P.
• Application Number:
  US15/376,416
• Publication Number:
  US 20170165908A1
• Time in Patent Office: 1,296 Days
• CPC Class Codes: A61F 2/0063 Implantable repair or support meshes, e.g. hernia meshes
• CPC Class Codes: A61F 2/06 Blood vessels
• CPC Class Codes: A61F 2/90 characterised by a net-like or mesh-like structure
• CPC Class Codes: A61F 2210/0057 stretchable
• CPC Class Codes: A61F 2240/002 Designing or making customized prostheses
• CPC Class Codes: A61F 2250/0012 for adjusting elasticity, flexibility, spring rate or mechanical tension
• CPC Class Codes: A61F 2250/0023 differing in porosity
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/20 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/232 for motion along the axis orthogonal to the plane of a layer
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2067/046 PLA, i.e. polylactic acid or polylactide
• CPC Class Codes: B29L 2031/726 Fabrics nets B29L2028/00
• CPC Class Codes: B29L 2031/7534 Cardiovascular protheses
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing

Abstract

Methods, systems, and devices for extrusion-based three-dimensional printing are provided. The methods, systems, and devices allow for the printing materials such as fabrics, clothing, and wearable and/or implantable devices. A number of different enhancements are provided that allow for this improved form of three-dimensional printing, including: (1) printing using a polymer (e.g., cellulose acetate) dissolved in a solvent (e.g., acetone); (2) selectively bonding portions of a deposited filament onto one or more surfaces and/or one or more previously deposited filaments; (3) using particular toolpaths to create a fabric or similar material by creating a woven pattern; and (4) printing across multiple layers even when previous layers are not complete. Other aspects of the present disclosure, including other enhancements and various printer configurations, are also provided.

Claims

1. A method for printing a surgical mesh or brace in three dimensions, the method comprising:

forming a three-dimensional template based on one or more structures of an anatomy of a patient;

depositing a filament onto at least one of a surface of the template or one or more previously deposited filaments on the three-dimensional template to form a multi-layered structure that conformably matches a shape of the three-dimensional template, said depositing taking place from one nozzle of a combination of warp nozzles and weft nozzles configured to advance along at least a first and second path, respectively; and

selectively modulating adhesion of the filament being deposited to the at least one of the surface or the one or more previously deposited filaments across a length of the filament being deposited to form a fabric such that some interfaces between the filament being deposited and the at least one of the surface or the one or more previously deposited filaments are bonded together at these some interfaces while some other interfaces between the filament being deposited and the at least one of the surface or the one or more previously deposited filaments are unbonded at these other interfaces.

2. The method of claim 1, wherein selectively modulating adhesion of the filament being deposited further comprises performing photopolymerization on a bonding agent that is in contact with the filament being deposited.

3. The method of claim 1, wherein selectively modulating adhesion of the filament being deposited further comprises at least one of:

(1) bringing the filament being deposited into contact with the at least one of the surface and the one or more previously deposited filaments;

(2) controlling a rate at which a solvent associated with the filament being deposited evaporates prior to the filament being deposited coming into contact with the at least one of the surface and the one or more previously deposited filaments;

(3) selectively exposing regions that include one or more filament interstices before, during, or after said depositing of the filament to one or more of light able to cure a photopolymer applied to the filament being deposited, or a material having light-responsive bonding agents associated therewith;

(4) selectively exposing regions that include one or more filament interstices to heat before, during, or after said depositing of the filament;

(5) selectively using an adhesive at regions that include one or more filament interstices during or after said depositing of the filament;

or (6) selectively using an adhesive to provide bonding between the filament being deposited and the one or more previously deposited filaments.

4. The method of claim 1, further comprising:

depositing one or more additional filaments onto at least one of the surface or the one or more previously deposited filaments; and

selectively modulating adhesion of the one or more additional filaments being deposited to the at least one of the surface or the one or more previously deposited filaments across a length of the one or more additional filaments being deposited such that some interfaces between the one or more additional filaments being deposited and the at least one of the surface or the one or more previously deposited filaments are bonded together at these some interfaces while some other interfaces between the one or more additional filaments being deposited and the at least one of the surface or the one or more previously deposited filaments are unbonded at these other interfaces.

5. The method of claim 4, further comprising locally adjusting at least one of an orientation, thickness, or composition of at least one of:

(a) the one or more previously deposited filaments or the one or more additional filaments, or (b) one or more adhesives used in conjunction with the one or more previously deposited filaments or the one or more additional filaments, the locally adjusting action resulting in the fabric having a varied mechanical response to application of an outside force across a surface area of the fabric.

6. The method of claim 5, wherein locally adjusting at least one of an orientation, thickness, or composition of at least one of:

(a) the one or more previously deposited filaments or the one or more additional filaments, or (b) one or more adhesives used in conjunction with the one or more previously deposited filaments or the one or more additional filaments further comprises at least one of;

(1) modulating shear stress of the fabric by changing interfilament bonding;

(2) modulating out-of-plane extension of the fabric in response to in-plane compression or tension of the fabric;

(3) modulating tensile stiffness of the fabric by modulating localized filament slack;

or (4) modulating Poisson'"'"'s ratio by modulating filament and bonding patterns.

7. The method of claim 4, wherein depositing one or more additional filaments onto at least one of the surface or the one or more previously deposited filaments occurs from one or more additional nozzles of the combination of warp nozzles and weft nozzles.

8. The method of claim 1, wherein the fabric has a varied mechanical response that results from a configuration of the fabric in which a first region across the surface area of the fabric has smaller pores formed between the filament being deposited and the one or more previously deposited filaments than pores formed between the filament being deposited and the one or more previously deposited filaments of a second region across the surface area of the fabric.

9. The method of claim 1, wherein selectively modulating adhesion of the filament being deposited controls one or more of the following fabric properties:

deformation, electrical conductivity, thermal conductivity, or toughness.

10. The method of claim 1, wherein the material of the filament being deposited and the one or more previously deposited filaments, or one or more adhesives used in conjunction with the filament being deposited and the one or more previously deposited filaments, comprises at least one of a thermoplastic polymer or a thermoset polymer.

11. The method of claim 1, wherein the filament being deposited and an adhesive used in conjunction with the filament being deposited comprise the same material.

12. The method of claim 1, further comprising:

dissolving a polymer in a solvent to form a viscous fluid,

wherein depositing a filament onto at least one of a surface or one or more previously deposited filaments further comprises extruding the viscous fluid through the one nozzle of the warp and weft nozzles to form the filament being deposited.

13. The method of claim 12, wherein extruding the viscous fluid through the one nozzle to form the filament being deposited further comprises:

positioning the nozzle at a first location with respect to the at least one of a surface or one or more previously deposited filaments;

depositing an initial portion of the filament being deposited from the nozzle at a first site on the at least one of a surface or one or more previously deposited filaments;

moving the nozzle to a second location with respect to the at least one of a surface or one or more previously deposited filaments while depositing an additional portion of the filament being deposited from the nozzle towards the at least one of a surface or one or more previously deposited filaments so as to stretch the additional portion of the filament being deposited;

positioning the nozzle at a third location with respect to the at least one of a surface or one or more previously deposited filaments; and

depositing an end portion of the filament being deposited from the nozzle at a second site on the at least one of a surface or one or more previously deposited filaments.

14. The method of claim 13, wherein moving the nozzle to a second location further comprises raising the nozzle to the second location with the second location being above the first location with respect to the at least one of the surface or the one or more previously deposited filaments.

15. The method of claim 14, wherein raising the nozzle to the second location further comprises accelerating the nozzle.

16. The method of claim 13, further comprising accelerating the nozzle after positioning the nozzle at the third location so as to straighten the additional portion of filament.

17. The method of claim 13, wherein the first and third locations are proximate to the surface.

18. The method of claim 1, wherein selectively modulating adhesion of the filament being deposited controls a shear modulus of the fabric.

19. The method of claim 1, wherein the surface is an adhesive surface.

20. The method of claim 1, wherein the filament being deposited is compromised of at least one of:

a continuous, pre-made filament, an adhesive-coated filament, or an adhesive filament.

21. The method of claim 1, wherein selectively modulating adhesion of the filament being deposited occurs during the step of depositing a filament onto the at least one of the surface or the one or more previously deposited filaments.

22. The method of claim 1, wherein the fabric is devoid of interstices at these some interfaces.

23. The method of claim 1, wherein selectively modulating adhesion of the filament being deposited occurs on a layer-by-layer basis.

24. The method of claim 1, further comprising imaging the one or more structures of the anatomy of the patient from which the three-dimensional template is formed.

25. A method for printing a surgical mesh or brace in three dimensions, the method comprising:

forming a three-dimensional template based on one or more structures of an anatomy of a patient;

positioning a nozzle at a first location with respect to at least one of a surface of the template or one or more previously deposited filaments, the nozzle being one nozzle of a combination of warp nozzles and weft nozzles configured to advance along at least first and second paths, respectively;

depositing a thermoplastic filament from the one nozzle to form a multi-layered fabric conformably matching a shape of the three-dimensional template, said depositing taking place by;

extruding an initial portion of thermoplastic filament from the nozzle at a first site of the at least one of the surface or the one or more previously deposited filaments on the three-dimensional template;

moving the nozzle to a second location with respect to the at least one of the surface or the one or more previously deposited filaments while extruding an additional portion of the thermoplastic filament from the nozzle towards the at least one of the surface or the one or more previously deposited filaments so as to stretch the additional portion of the filament being deposited, the second location being above the first location with respect to the at least one of the surface or the thermoplastic filament that has been extruded such that said moving the nozzle to the second location includes raising the nozzle, and the nozzle accelerating during movement to the second location;

positioning the nozzle at a third location with respect to the at least one of the surface or the one or more previously deposited filaments; and

extruding an end portion of the thermoplastic filament from the nozzle at a second site of the at least one of the surface or the one or more previously deposited filaments.

26. The method of claim 25, further comprising selectively modulating adhesion of the thermoplastic filament being extruded on the at least one of the surface or the one or more previously deposited filaments.

27. The method of claim 26, wherein selectively modulating adhesion of the thermoplastic filament being extruded occurs during said extrusion of the thermoplastic filament.

28. The method of claim 26, wherein selectively modulating adhesion of the thermoplastic filament being extruded further comprises at least one of:

(1) bringing the thermoplastic filament being extruded into contact with the at least one of the surface and the one or more previously deposited filaments;

(2) controlling a rate at which a solvent associated with the thermoplastic filament being extruded evaporates prior to the thermoplastic filament being extruded coming into contact with the at least one of the surface and the one or more previously deposited filaments;

(3) selectively exposing regions that include one or more filament interstices before, during, or after said depositing of the filament to one or more of light able to cure a photopolymer applied to the filament being deposited, or a material having light-responsive bonding agents associated therewith;

(4) selectively exposing regions that include one or more filament interstices to heat before, during, or after said depositing of the thermoplastic filament;

(5) selectively using an adhesive at regions that include one or more filament interstices during or after said depositing of the thermoplastic filament;

or (6) selectively using an adhesive to provide bonding between the thermoplastic filament being extruded and the one or more previously deposited filaments.

29. The method of claim 26, further comprising:

positioning the nozzle with respect to the at least one of a surface or one or more previously deposited filaments;

extruding one or more additional thermoplastic filaments from the nozzle;

moving the nozzle to another location with respect to the at least one of the surface or the one or more previously deposited filaments while extruding a portion of the one or more additional thermoplastic filaments from the nozzle towards the at least one of the surface or the one or more previously deposited filaments so as to stretch the portion of the one or more additional thermoplastic filaments, the another location being above the location at which extrusion of the one or more additional thermoplastic filaments began such that said moving the nozzle includes raising the nozzle, and the nozzle accelerating during movement to the another location; and

extruding an end portion of the one or more additional thermoplastic filaments from the nozzle on the at least one of the surface or the one or more previously deposited filaments.

30. The method of claim 26, further comprising:

dissolving a thermoplastic polymer in a solvent to form a viscous fluid,

wherein said extruding of an initial portion of a thermoplastic filament from the nozzle at a first site of the at least one of the surface or one or more previously deposited filaments further comprises extruding the viscous fluid through the nozzle to form the thermoplastic filament being extruded.

31. The method of claim 25, further comprising imaging the one or more structures of the anatomy of the patient from which the three-dimensional template is formed.

32. The method of claim 25, further comprising:

positioning one or more additional nozzles of the combination of warp nozzles and weft nozzles with respect to the at least one of a surface or one or more previously deposited filaments;

extruding one or more additional thermoplastic filaments from the one or more additional nozzles;

moving the one or more additional nozzles to another location with respect to the at least one of the surface or the one or more previously deposited filaments while extruding a portion of the one or more additional thermoplastic filaments from the one or more additional nozzles towards the at least one of the surface or the one or more previously deposited filaments so as to stretch the portion of the one or more additional thermoplastic filaments, the another location being above the location at which extrusion of the one or more additional thermoplastic filaments began such that said moving the one or more additional nozzles includes raising the one or more additional nozzles, and the one or more additional nozzles accelerating during movement to the another location; and

extruding an end portion of the one or more additional thermoplastic filaments from the one or more additional nozzles on the at least one of the surface or the one or more previously deposited filaments.