Digital Light Processing (DLP) enables high precision 3D-printing of photopolymers and holds promising potential for patient-specific implant solutions. On the material side, Poly(ethylene glycol) diacrylate (PEGDA) has emerged as an interesting material for use in biomedical applications. For adequate photopolymerization, a photoinitiator and a light absorber are necessary, using welldefined concentrations. This study shows preliminary results of DLP 3D-printing of different PEGDA hydrogel compositions with varying water content (90; 70; 50; 30; 10; 0 % w/w) as well as varying concentrations of a photoinitiator and a light absorber. Printing performance and accuracy are investigated by printing rectangular test samples as well as an anatomically customised tubular frontal sinus implant prototype. For basic mechanical characterisation, the hardness of the printed hydrogels is investigated using a Shore A durometer. The results show a decrease in printing accuracy and hardness with an increasing water content of the composition. There is a need to use a light absorber to reach high printing accuracy. This leads to a need for increasing photoinitiator concentration and prolonged light exposure to achieve proper printing performance.
A new approach that offers the potential for local drug delivery to the inner ear is a 3D printed, patient individualized, drug-loaded implant that precisely fits into the round window niche (RWN). Anatomically correct digital light processing (DLP) 3D printed implant prototypes are beneficial for preoperative planning and rehearsal of implantation techniques due to tactile feedback. The aim is to define desired mechanical material properties for future RWN implants. For this purpose, RWN implant prototypes (RWN-IPs) were DLP 3D printed using commercially available E-Shell 500 and E-Shell 600 materials (Envisiontec GmbH, Gladbeck, Germany) and a selfestablished PEGDA700 composition. These photopolymers are suitable for 3D printing RWN-IPs that feature different mechanical characteristics. The (1) mechanical properties (tensile test) were investigated, (2) the implantation feasibility and (3) fitting accuracy in human cadaver RWN were evaluated. As a result, E-Shell 500 has relatively high stretchability (ɛm ~ 60%) while E-Shell 600 and PEGDA700 are brittle and PEGDA700 has low strength. The E-Shell 500 material performs by far the best at handling and insertion. EShell 600 has adequate strength but is hard to handle because of rigid material behavior. PEGDA700 enables high 3D printing accuracy but lacks adequate mechanical behavior for adequate insertion of implant prototypes in RWN.
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