Methods for fabricating a filament for use in tissue engineering
First Claim
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1. A method for fabricating a filament for use in tissue engineering, said method comprising:
- providing a polycaprolactone material;
melting said polycaprolactone material at a first given temperature to form a polycaprolactone melt;
holding the temperature of said polycaprolactone melt at said first given temperature for a given amount of time;
lowering the temperature of said polycaprolactone melt from said first given temperature to a second given temperature after the step of holding the temperature of said polycaprolactone melt at said first given temperature for said given amount of time;
extruding said polycaprolactone melt through a fiber-spinning machine, said fiber-spinning machine having spinnerets with a die exit of a given diameter, a piston set at a given speed, and a vertical drop of a given distance from said die exit to a cooling material positioned below said die exit, wherein the combination of said second given temperature, said given die exit diameter, said given piston speed, and said given distance of said vertical drop produces said filament with a given diameter for use in tissue engineering.
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Abstract
The invention relates to the use of Fused Deposition Modeling to construct three-dimensional (3D) bioresorbable scaffolds from bioresorbable polymers such as polycaprolactone (PCL), or from composites of bioresorbable polymers and ceramics, such as polycaprolactone/hydroxyapatite (PCL/HA). Incorporation of a bioresorbable ceramic to produce a hybrid/composite material support provides the desired degradation and resorption kinetics. Such a composite material improves the biocompatibility and hard tissue integration and allows for increased initial flash spread of serum proteins. The basic resorption products of the composite also avoids the formation of an unfavorable environment for hard tissue cells due to a decreased pH. The scaffolds have applications in tissue engineering, e.g., in tissue engineering bone and cartilage.
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Citations
39 Claims
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1. A method for fabricating a filament for use in tissue engineering, said method comprising:
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providing a polycaprolactone material;
melting said polycaprolactone material at a first given temperature to form a polycaprolactone melt;
holding the temperature of said polycaprolactone melt at said first given temperature for a given amount of time;
lowering the temperature of said polycaprolactone melt from said first given temperature to a second given temperature after the step of holding the temperature of said polycaprolactone melt at said first given temperature for said given amount of time;
extruding said polycaprolactone melt through a fiber-spinning machine, said fiber-spinning machine having spinnerets with a die exit of a given diameter, a piston set at a given speed, and a vertical drop of a given distance from said die exit to a cooling material positioned below said die exit, wherein the combination of said second given temperature, said given die exit diameter, said given piston speed, and said given distance of said vertical drop produces said filament with a given diameter for use in tissue engineering. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method for fabricating a filament for use in tissue engineering, said method of fabricating said filament comprising:
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providing polycaprolactone pellets;
melting said polycaprolactone pellets at about 190°
C. to form a polycaprolactone melt;
holding the temperature of said polycaprolactone melt at about 190°
C. for about 15 minutes;
lowering the temperature of said polycaprolactone melt from said first given temperature to about 140°
C. after the step of holding the temperature of said polycaprolactone melt at about 190°
C. for about 15 minutes; and
extruding said polycaprolactone melt through a fiber-spinning machine, said fiber-spinning machine having spinnerets with a die exit of about 1.63 mm, a piston set at about 10 mm/min, and a vertical drop of about 40 mm from said die exit to water positioned below said die exit, wherein the combination of said lower temperature of about 140°
C., said die exit diameter of about 1.63, said piston speed of about 10 mm/min, and said vertical drop of about 40 mm produces said filament with a given diameter for use in tissue engineering;
wherein said given diameter of said filament corresponds to drive wheels of an unmodified Fused Deposition Modeling (FDM) system;
wherein said filament is configured to have a constant diameter; and
wherein said filament is vacuum-dried and kept in a dessicator prior to usage.
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18. A method for fabricating a filament for use in tissue engineering, said method comprising:
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providing a polycaprolactone material;
drying said polycaprolactone material at a first given temperature for a first given amount of time to form a dried polycaprolactone material;
combining said dried polycaprolactone material with a HA and methylene chloride mixture to form a PCL/HA blend;
stirring said PCL/HA blend at a second given temperature for a second given amount of time to form a solvent mixture;
casting said solvent mixture on a tray at a third given temperature for a third given amount of time to evaporate said solvent mixture to form a PCL/HA composite foam material;
melting said PCL/HA composite foam material at a fourth given temperature to form a PCL/HA melt;
holding the temperature of said PCL/HA melt at said fourth given temperature for a fourth given amount of time;
lowering the temperature of said PCL/HA melt from said fourth given temperature to a fifth given temperature after the step of holding the temperature of said PCL/HA melt at said fourth given temperature for said fourth given amount of time; and
extruding said PCL/HA melt through a fiber-spinning machine, said fiber spinning machine having spinnerets with a die exit of a given diameter, a piston set at a given speed, and a vertical drop of a given distance from said die exit to a cooling material positioned below said die exit, wherein the combination of said fifth given temperature, said given die exit diameter, said given piston speed, and said given distance of said vertical drop produces said filament with a given diameter for use in tissue engineering. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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Specification
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Current AssigneeOsteopore International, Ltd., Osteopore International Pte Ltd.
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Original AssigneeDietmar Werner Hutmacher, Iwan Zein, Kim Cheng Tan, Kock Fye Tam, Swee Hin Teoh
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InventorsZein, Iwan, Teoh, Swee Hin, Tan, Kim Cheng, Tam, Kock Fye, Hutmacher, Dietmar Werner
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Primary Examiner(s)Tentoni, Leo B.
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Application NumberUS09/957,407Time in Patent Office957 DaysField of Search264/178.F, 264/211.14, 264/234US Class Current264/178.00FCPC Class CodesA61F 2/30756 Cartilage endoprostheses A6...A61L 27/18 obtained otherwise than by ...A61L 27/46 with phosphorus-containing ...A61L 27/58 Materials at least partiall...B33Y 10/00 Processes of additive manuf...B33Y 70/00 Materials specially adapted...B33Y 70/10 Composites of different typ...B33Y 80/00 Products made by additive m...C08L 67/04 Polyesters derived from hyd...D01F 6/625 derived from hydroxy-carbox...
