Optimization of FDM 3D printing process parameters to produce haemodialysis curcumin-loaded vascular grafts

Sara Basile,Ida Genta,Bice Conti,Rossella Dorati,Essyrose Mathew,Dimitrios A Lamprou

doi:10.1007/s13346-021-01078-2

Abstract

3D printing has provided a new prospective in the manufacturing of personalized medical implants, including fistulas for haemodialysis (HD). In the current study, an optimized fused modelling deposition (FDM) 3D printing method has been validated, for the first time, to obtain cylindrical shaped fistulas. Printing parameters were evaluated for the manufacturing of fistulas using blank and 0.25% curcumin-loaded filaments that were produced by hot melt extrusion (HME). Four different fistula types have been designed and characterized using a variety of physicochemical characterization methods. Each design was printed three times to demonstrate printing process accuracy considering outer and inner diameter, wall thickness, width, and length. A thermoplastic polyurethane (TPU) biocompatible elastomer was chosen, showing good mechanical properties with a high elastic modulus and maximum elongation, as well as stability at high temperatures with less than 0.8% of degradation at the range between 25 and 250 °C. Curcumin release profile has been evaluated in a saline buffer, obtaining a low release (12%) and demonstrating drug could continue release for a longer period, and for as long as grafts should remain in patient body. Possibility to produce drug-loaded grafts using one-step method as well as 3D printing process and TPU filaments containing curcumin printability has been demonstrated.Graphical abstract

Highlights

Chronic kidney disease (CKD) is a pathologic condition characterized by the decreased function and altered structure of the kidneys
Haemodialysis (HD) is a technique where blood circulates through dialyser membrane channels, while the dialysis fluid with an electrolyte composition like extracellular fluid is passing outside these channels in the opposite direction, in order to eliminate wastes from the patient blood [4]
Three samples for each design were printed with an outer diameter (OD) of 6.0 mm, an inner diameter (ID) of 4.0 mm and a wall thickness of 2.0 mm (Fig. 2)

Summary

Introduction

Chronic kidney disease (CKD) is a pathologic condition characterized by the decreased function and altered structure of the kidneys. In 2017, there were 697.5 million cases of CKD in the world, with 9.1% of prevalence and 1.2 million deaths [2]. According to the World Health Organization (WHO), from 2000 to 2019, kidney diseases have risen from the world’s 13th leading cause of death to the 10th. When impaired kidneys are functional only at 10–15%, patients undergo a dialysis treatment for replacing healthy kidneys [1]. Haemodialysis (HD) is a technique where blood circulates through dialyser membrane channels, while the dialysis fluid with an electrolyte composition like extracellular fluid is passing outside these channels in the opposite direction, in order to eliminate wastes from the patient blood [4]

Methods

Results

Conclusion