BACKGROUND

3D printing technology is applied in various industries for manufacturing and planning. For example, the automotive, aerospace and consumer goods industries use 3D printing to create prototypes of parts and products. 3D printing has also been used in the architectural industry for printing structural models. The applications of 3D printing in private and government defense have grown rapidly as well.

3D printing has had a significant impact in the medical fields. Medical applications of 3D printing date back to the early 2000s, for example, with the production of dental implants and prosthetics. 3D printing has also been used in the fabrication of drug delivery devices that can be used for direct treatment. A variety of drug delivery devices may be created which allow for customizable drug release profiles.

Traditional 3D printing allows an object to be created by depositing a material over a flat fabrication platform one layer at a time. Once a first layer is deposited, a second layer is deposited on top of the first layer. The process is repeated as necessary to create a multi-laminate solid object. However, 3D printing does not allow for continuous extrusion to create an object.

Conventionally, bone tissue regeneration is achieved by filling a bone repair site with a bone graft. Over time, the bone graft is incorporated by the host and new bone remodels the bone graft. In order to place the bone graft, it is common to use a monolithic bone graft or to form an osteoimplant comprising particulated bone in a carrier. The carrier is thus chosen to be biocompatible, to be resorbable, and to have release characteristics such that the bone graft is accessible. Generally, the formed implant, whether monolithic or particulated and in a carrier, are substantially solid at the time of implantation and thus do not conform to the implant site. Further, the implant is substantially complete at the time of implantation and thus provides little ability for customization, for example by the addition of autograft.

Traditional methods of 3D printing allows for objects to be created through layered stratification of print material onto a flat surface. The layered stratified products created through traditional 3D printing lack the strength and flexibility necessary to make a hollow implant. As such, a suitable implant having a hollow center for particulated bone or other osteogenic materials is difficult to manufacture through traditional 3D printing methods.

Thus, there is a need for a 3D printing device that can manufacture hollow structures for implantable medical devices, such as for example, mesh covering or bags that are strong, flexible, stretchable and biocompatible. There is a need for a 3D printing device having a rotatable printing surface that allows continuous extrusion instead of stratified layers to manufacture hollow structures for implantable medical devices.

SUMMARY

Provided are 3D printing devices and methods of use for creating hollow structures such as mesh bags. Also provided are 3D printing devices including a rotatable printing surface to create such hollow structures. Further provided are devices and methods for 3D printing onto such a rotatable printing surface by continuous extrusion instead of stratified layers. Additionally, provided are devices and methods for creating structures having a meshed design that are strong, flexible, stretchable and biocompatible. In some embodiments, because the implant is printed continuously, there is no need to seal all sides of the implant, at most two sides or one side of the implant.

According to one aspect, provided is a device for making an implant having a hollow region, the device comprising a print surface rotatable in a clockwise and counterclockwise direction about an axis of rotation; a print head disposed adjacent to and substantially transverse to the print surface, the print head configured to apply material used to make the implant on at least a portion of the print surface or heat material disposed on at least a portion of the print surface used to make the implant; and a base disposed adjacent to the print head and contacting the print surface, the base configured to be movable in forward, backward and lateral directions relative to the print head to make the implant having the hollow region.

According to another aspect, provided is a device for making an implant having a hollow region, the device comprising a print surface rotatable in a clockwise and counterclockwise direction about an axis of rotation relative to a print head, and at least one of (i) the print surface configured to be movable in forward and backward directions relative to the print head or (ii) the print head configured to be movable in forward and backward directions relative to the print surface, the print head disposed adjacent to and substantially transverse to the print surface; and the print head configured to apply material used to make the implant on at least a portion of the print surface or heat material disposed on at least a portion of the print surface used to make the implant having the hollow region.

According to yet another aspect, provided is a method for making an implant having a hollow region, the method comprising applying a material used to make the implant having the hollow region on a device having a print surface, the device having the print surface rotatable in a clockwise and counterclockwise direction about an axis of rotation, a print head disposed adjacent to and substantially transverse to the print surface, the print head configured to apply the material used to make the implant on at least a portion of the print surface or heat material applied on at least the portion of the print surface used to make the implant, a base disposed adjacent to the print head and contacting the print surface, the base configured to be movable in forward, backward and lateral directions relative to the print head to make the implant having the hollow region.

According to yet another aspect, provided is a computer-implemented method for creating hollow structures, the method comprising inputting instructions to direct a processor, the processor configured to induce rotation of a print surface in alternating clockwise and counterclockwise directions, and ejection of material from a print head to the print surface to make a strand having a wave-like pattern with alternating peaks and crests, and rotating the print head such an angular distance to create a plurality of interconnected strands on the print surface.

While multiple embodiments are disclosed, still other embodiments of the present application will become apparent to those skilled in the art from the following detailed description, which is to be read in connection with the accompanying drawings. As will be apparent, the present disclosure is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present disclosure. Accordingly, the detailed description is to be regarded as illustrative in nature and not restrictive.

