3D-printed Mesh Research Articles

Customized 3D-Printed Mesh, Membrane, Bone Substitute, and Dental Implant Applied to Guided Bone Regeneration in Oral Implantology: A Narrative Review.

Background: The new frontiers of computer-based surgery, technology, and material advances, have allowed for customized 3D printed manufacturing to become widespread in guided bone regeneration (GBR) in oral implantology. The shape, structural, mechanical, and biological manufacturing characteristics achieved through 3D printing technologies allow for the customization of implant-prosthetic rehabilitations and GBR procedures according to patient-specific needs, reducing complications and surgery time. Therefore, the present narrative review aims to elucidate the 3D-printing digital radiographic process, materials, indications, 3D printed manufacturing-controlled characteristics, histological findings, complications, patient-reported outcomes, and short- and long-term clinical considerations of customized 3D printed mesh, membranes, bone substitutes, and dental implants applied to GBR in oral implantology. Methods: An electronic search was performed through MEDLINE/PubMed, Scopus, BioMed Central, and Web of Science until 30 June 2024. Results: Three-dimensionally printed titanium meshes and bone substitutes registered successful outcomes in vertical/horizontal bone defect regeneration. Three-dimensionally printed polymeric membranes could link the advantages of conventional resorbable and non-resorbable membranes. Few data on customized 3D printed dental implants and abutments are available, but in vitro and animal studies have shown new promising designs that could improve their mechanical properties and tribocorrosion-associated complications. Conclusions: While 3D printing technology has demonstrated potential in GBR, additional human studies are needed to evaluate the short- and long-term follow-up of peri-implant bone levels and volumes following prosthetic functional loading.

A preliminary study of the mechanical properties of 3D-printed personalized mesh titanium alloy prostheses and repair of hemi-mandibular defect in dogs.

This study is a preliminary investigation exploring the mechanical properties of three-dimensional (3D)-printed personalized mesh titanium alloy prostheses and the feasibility of repairing hemi-mandibular defects. The ANSYS 14.0 software and selective laser melting (SLM) were used to produce personalized mesh titanium alloy scaffolds. Scaffolds printed using different parameters underwent fatigue property tests and scanning electron microscopy (SEM) of the fracture points. Models of hemi-mandibular defects (encompassing the temporomandibular joint) were created using beagle dogs. Freeze-dried allogeneic mandibles or 3D-printed personalized mesh titanium alloy prostheses were used for repair. Gross observation, computed tomography (CT), SEM, and histological examinations were used to compare the two repair methods. The prostheses with filament diameters of 0.5 and 0.7 mm could withstand 14,000 times and >600,000 cycles of alternating stresses, respectively. The truss-structure scaffold with a large aperture and large aperture ratio could withstand roughly 250,000 cycles of alternating forces. The allogeneic mandible graft required intraoperative shaping, while the 3D-printed mesh titanium alloy prostheses were personalized and did not require intraoperative shaping. The articular disc on the non-operated sides experienced degenerative changes. No liver and kidney toxicity was observed in the two groups of animals. The 3D-printed mesh titanium alloy prostheses could effectively restore the shape of the mandibular defect region and reconstruct the temporomandibular joint.

A 3D-printed multi-compartment organ-on-chip platform with a tubing-free pump models communication with the lymph node.

Multi-organ-on-chip systems (MOOCs) have the potential to mimic communication between organ systems and reveal mechanisms of health and disease. However, many existing MOOCs are challenging for non-experts to implement, due to complex tubing, electronics, or pump mechanisms. In addition, few MOOCs have incorporated immune organs such as the lymph node (LN), limiting their applicability to critical events such as vaccination. Here we developed a 3D-printed, user-friendly device and companion tubing-free impeller pump with the capacity to co-culture two or more tissue samples, including a LN, under a recirculating common media. Native tissue structure and immune function were incorporated by maintaining slices of murine LN tissue ex vivo in 3D-printed mesh supports for at least 24 hr. In a two-compartment model of a LN and an upstream injection site in mock tissue, vaccination of the multi-compartment chip was similar to in vivo vaccination in terms of locations of antigen accumulation and acute changes in activation markers and gene expression in the LN. We anticipate that in the future, this flexible platform will enable models of multi-organ immune responses throughout the body.

Synchronous semi-solid extrusion and photopolymerization of antimicrobial dressing hydrogel for wound healing

Bacterial infections at wound sites require more time for a fast and efficient wound-healing process. Antibacterial methyl cellulose-based hydrogel wound dressing can be an excellent option because it can show antibacterial action, absorb wound exudates, and have a cooling and soothing effect on the wound bed. The ultraviolet (UV) ray-assisted semi-solid extrusion 3D printing technique was used to prepare 3D printed construct into a high surface area mesh-like structure utilizing UV radiation for photocrosslinking of hydrogel matrix in the presence of Poly (ethylene glycol) Diacrylate. The prepared hydrogel was characterized for contact angle, and rheological analysis before semi-solid extrusion-based 3D printing. After optimization of printing parameters, the 3D printed mesh was subjected to physicochemical characterizations like dimensional analysis, swelling study, drug content, in vitro drug release, and in vitro antimicrobial activity study. A rheological analysis confirmed the viscosity, thixotropy, and viscoelastic nature of prepared hydrogel. Drug release study showed approximately 50 % release in 4 h, and >80 % drug release in 24 h. After optimization of one batch, hydrogel polymerization was done by functional group analysis followed by validation of thread thickness by electron microscopy images and mechanical property assessment. The 3D-printed mesh was further evaluated for its in-vitro antibacterial performance against Escherichia coli and Staphylococcus aureus. The area of inhibition was one-fold more in Staphylococcus aureus and two-fold in E. coli, ensuring diffusion of the drug from 3D printed mesh and killing of bacteria. The work reported herein represents a universal platform to generate multifunctional and customized hydrogels with various functional substances for wound dressing applications.

Surgical Planning and 3D-Printed Mesh Implant for Effective Bone Gap Management: A Case Report

Introduction: Critical-size bone defects in distal tibial open wounds pose a formidable challenge, requiring interventions that can address osseous reconstruction with less number of surgeries. Current treatment modalities may fall short in achieving optimal outcomes, with respect to early weight bearing due to the inability of the graft to sustain weight, graft-related infections, non-union in large defects, donor site morbidity, and non-availability of bone grafts due to earlier harvest. This case report explores the potential application of a 3D-printed mesh implant to this complex clinical scenario. Case Report: A 38-year-old male, post-road traffic accident, presented with an inability to walk due to fractures of the medial malleolus and distal tibia-fibula with a grade 3b open wound. Initial treatment was done with an external fixator and fibula plating, with the fixator removed after 5 months. The fracture showed atrophic non-union and a 2.5 cm limb shortening at the end of 5 months. Preferring thick flap incisions, the patient operated with a 3D-printed titanium mesh implant with a plate construct. Post-surgery, we followed a non-weight-bearing regime for 1.5 months, progressing to full weight-bearing by 3 months. At 1.5 years, CT scans confirmed good bone integration and ambulation restoration. Conclusion: The use of 3D-printed mesh implants may be a viable option for managing critical-size bone defects in distal tibial open wounds. Porotic nature of mesh implant facilitates bone ingrowth in large gaps. Keywords: 3D-printing, mesh implant, non-union.

Energy Absorption by 3D-Printed Mesh Structures with a Negative Poisson’s Ratio

Energy Absorption by 3D-Printed Mesh Structures with a Negative Poisson’s Ratio

Is three-dimension-printed mesh scaffold an alternative to reconstruct cavity bone defects near joints?

Reconstruction of cavity bone defects after curettage of benign bone tumours around the joint remains challenging. We designed a novel 3D-printed mesh scaffold as a substitute for bone cement, aiming to support the articular surface, protect the subchondral bone, and reduce complication rates. We retrospectively analyzed seven patients who received curettage and reconstruction using a 3D-printed mesh scaffold between January 2020 and June 2021. Pain and function were evaluated using the 10-cm Visual Analogue Scale (VAS) score and the 1993 version of the Musculoskeletal Tumor Society (MSTS-93) score. Radiographs were used to evaluate articular surface supporting, subchondral bone protection, and complications. The median functional MSTS-93 and VAS scores were both improved after surgery, and the median 3D-printed mesh scaffold volume was smaller than the median defect volume. Articular surface supporting, subchondral bone preservation, and osteogenesis were observed post-operatively. No related complications were observed during the last follow-up. The 3D-printed mesh scaffold provided sufficient mechanical support for the articular surface and protected the subchondral bone. We recommended the 3D-printed mesh structure as an alternative to repair cavity bone defects around joints.

Understanding and exploiting crystal formation during sodium chloride crystallization on 3D-printed mesh materials

Though crystallization is one of the oldest separation and purification processes, understanding and controlling it can be challenging. In this study, 3D-printed meshes were developed and tested for sodium chloride (NaCl) crystallization in two different configurations: one involving a stagnant NaCl solution and one using a flow-through crystallizer. Experiments with the stagnant NaCl solution investigated the effect of the coverage of the 3D-printed meshes and the roughness on solid salt recovery and size, while the flow-through crystallizer testing investigated the effect of solution/air interfaces in contact with the mesh on solid salt recovery and size. Higher solid salt recoveries were achieved for a mesh with a coverage of 52.24% and by increasing the solution/air interfaces in contact with the meshes; roughness changes did not have any significant effect on solid salt recovery. Finally, a potential mechanism explaining the salt formation from the solution/air interface towards the non-immersed portion of the mesh was developed.

Three-Dimensional Printed Mesh-Cage Replacement for a Metastatic Spinal Tumor and a Vertebral Compression Fracture: A Report of Two Cases

Harms mesh cages are commonly used in the treatment of metastatic spinal tumors by spondylectomy with cage insertion and posterior screw fixation. These cages are even useful for the surgical reconstruction of spinal deformities with mesh-cage replacement after vertebral column resection (VCR). Mesh cages can be customized by 3-dimensional (3D) printing based on the angle between the endplates for the requisite weight-bearing capacity and fit. This study reports two cases wherein a 75-year-old man and a 63-year-old woman were treated with reconstructive spondylectomy and mesh-cage replacement, followed by posterior screw fixation. The 75-year-old man was initially diagnosed with an L4 metastatic non–small cell lung carcinoma accompanied by a pathologic fracture and severe paralysis. The 63-year-old woman had slipped 13 years before and sustained a T11-L1 compression fracture that was aggravated 6 months before this admission, with back pain and numbness in both soles. Herein, we describe the treatment approach with instrumentation using a customized 3D-printed mesh cage after total spondylectomy for the metastatic spinal tumor and after VCR for deformity repair surgery in the respective cases. Our application of a 3D-printed mesh cage in surgery for a metastatic tumor is the first report of such treatment in Korea. Although the use of customized 3D-printed cages for a metastatic spinal tumor and a severe compression fracture was effective, challenges remain regarding fitting, manufacturing time, and costs.

Mesh Ti6Al4V Material Manufactured by Selective Laser Melting (SLM) as a Promising Intervertebral Fusion Cage.

Intervertebral cages made of Ti6Al4V alloy show excellent osteoconductivity, but also higher stiffness, compared to commonly used polyether-ether-ketone (PEEK) materials, that may lead to a stress-shielding effect and implant subsidence. In this study, a metallic intervertebral fusion cage, with improved mechanical behavior, was manufactured by the introduction of a three-dimensional (3D) mesh structure to Ti6Al4V material, using an additive manufacturing method. Then, the mechanical and biological properties of the following were compared: (1) PEEK, with a solid structure, (2) 3D-printed Ti6Al4V, with a solid structure, and (3) 3D-printed Ti6Al4V, with a mesh structure. A load-induced subsidence test demonstrated that the 3D-printed mesh Ti6Al4V cage had significantly lower tendency (by 15%) to subside compared to the PEEK implant. Biological assessment of the samples proved that all tested materials were biocompatible. However, both titanium samples (solid and mesh) were characterized by significantly higher bioactivity, osteoconductivity, and mineralization ability, compared to PEEK. Moreover, osteoblasts revealed stronger adhesion to the surface of the Ti6Al4V samples compared to PEEK material. Thus, it was clearly shown that the 3D-printed mesh Ti6Al4V cage possesses all the features for optimal spinal implant, since it carries low risk of implant subsidence and provides good osseointegration at the bone-implant interface.

3D-printed mesh membranes with controllable wetting state for directional droplet transportation

Mesh membranes have a wide range of applications including fog harvesting and oil-water separation. However, due to the wetting energy barrier, water droplets are usually pinned in the meshes and there are still substantial difficulties in achieving directional transport. In this paper, mesh membranes for directional droplet transport are achieved by controlling the surface wetting state with sub-millimeter structures. The effect of mesh structures on the surface wetting state is studied theoretically. And accordingly, a unique filament stack structure is presented to acquire the desired wetting state, which can be further switched on-demand by incorporating the filament swelling. The well-designed mesh structures can be 3D printed efficiently without post-processes such as surface modification. It provides a facile and effective way to develop scalable mesh membranes for directional and selective droplet transport.

Enhancement of devolatilization performance in a rotating packed bed with different packing structures

• The 3D-printed mesh packing with drop-shaped fibers (PMP-D) was manufactured. • The PMP-D was employed to enhance the devolatilization performance in RPB. • Compared with traditional SMP, the η and K L a of PMP-D was drastically improved. • Correlations to predict K L a were established with deviations less than ±20%. The devolatilization of volatile organic compounds (VOCs) from the viscous liquid like polymers was necessary but of great challenge caused by the high viscosity. In this work, different packing structures were manufactured in a rotating packed bed (RPB), including the stainless steel wire mesh packing (SMP), 3D-printed column packing (PCP), 3D-printed mesh packing with circular fibers (PMP-C), and 3D-printed mesh packing with drop-shaped fibers (PMP-D). The devolatilization performance of the RPB was investigated with the acetone-silicon oil working system. Results indicated that modifying the fiber shape of packing effectively intensified the devolatilization in the RPB. The removal efficiency ( η ) and volumetric mass transfer coefficient ( K L a ) of the PMP-D were dramatically larger than the other three packings. Compared the PMP-D with the traditional SMP, the maximum η was enhanced from 40% to 50%, and the increment of K L a was 50% on average. The correlations to predict K L a were established, and the deviations from the experimental results were less than ± 20%.

Direct recovery of spilled oil using hierarchically porous oil scoop with capillary-induced anti-oil-fouling

The pitcher plant has evolved its hierarchically grooved peristome to enhance a water-based slippery system for capturing insects with oil-covered footpads. Based on this, we proposed a hierarchically porous oil scoop (HPOS) with capillary-induced oil peel-off ability for repeatable spilled oil recovery. As the HPOS scoops oil-water mixture, water passes through the hole while the oil is confined within a curved geometry. The filter in HPOS has three levels of porous structures; (1) 3D-printed mesh structure with sub-millimeter scale hole to filter out oil from an oil–water mixture, (2) internal micropore in fibers enhancing capillarity and water transport, (3) O2 plasma-induced high-aspect-ratio nanopillar structures imposing anti-oil-fouling property with capillary-induced oil peeling. As the oil-contaminated HPOS makes contact with water, water meniscus rises and peels off the oil immediately at the air-water interface. The oil-peel-off ability of the HPOS would prevent pores from clogging by oils for reuse. The study demonstrated that the HPOS recovers highly viscous oil (up to 5000 mm2·s–1) with a high recovery rate (>95%), leaving the filtered water with low oil content (<10 ppm), which satisfies the discharge criterion of 15 ppm.

3D-Printed Anti-Fouling Cellulose Mesh for Highly Efficient Oil/Water Separation Applications.

The ability of additive manufacturing to print mesh structure was exploited to fabricate highly efficient filtration meshes for oil/water separation applications. Through Direct Ink Writing (DIW) technique, pure cellulose acetate with a mesh architecture can be created easily, using cellulose acetate/ethyl acetate solution as the ink and simply drying off the solvent in ambient conditions. Besides conventional mesh structures, more complex structures can be fabricated in order to manipulate the pore size and hence tune the separation properties of the mesh. The superhydrophilic 3D-printed cellulose meshes are able to achieve a high separation efficiency of >95% as long as the average pore size is smaller than 280 μm. More importantly, the mesh that possesses an unconventional complex structure boasts a separation efficiency of ∼99% while maintaining a high water flux of ∼160 000 Lm2-h-1. The 3D-printed cellulose meshes are also able to separate oil substances of a wide range of viscosity, from highly viscous PDMS (∼97 cP) to nonviscous cyclohexane (∼1 cP) and are chemically resistant to extreme acidic and alkaline conditions. Moreover, the 3D-printed cellulose meshes also possess antioil-fouling/self-cleaning ability, which makes its surfaces resilient to contamination. In addition, the 3D-printed meshes do not suffer from surface inhomogeneity and interfacial adhesion issues as compared to the usual coated meshes. Such a robust yet practical system is highly applicable for highly efficient oil-water separation applications.