Efficient generation strategy for hierarchical porous scaffolds with freeform external geometries

Abstract The external geometry design and manipulation of internal porosity distribution according to the actual application demands are the main challenges of scaffold generation; moreover, computational efficiency is a key factor that should be considered. This paper proposes efficient generation strategies for constructing internal porous architectures by using triply periodic minimal surfaces (TPMSs) and external freeform shapes through T-spline surfaces. After discretizing the geometries as slicing contours, TPMSs can be efficiently extracted using the intersection-interpolation method in 2D space, and then be offset as infill areas of sheet solids. Based on the proposed fractal sheet TPMSs, hierarchical scaffolds are further generated using the refined constrained Delaunay triangulation method to construct multiscale pores. The porosity features can be conveniently controlled in 2D space according to the actual computed tomography images. Eventually, the resulting infill areas can be directly fabricated as scaffolds by additive manufacturing technology. Several experimental instances validate the effectiveness and efficiency of the proposed strategies.

[1]  Yang Ju,et al.  3D numerical reconstruction of well-connected porous structure of rock using fractal algorithms , 2014 .

[2]  F. Martina,et al.  Design for Additive Manufacturing , 2019 .

[3]  D. Yoo.  Porous scaffold design using the distance field and triply periodic minimal surface models. , 2011, Biomaterials.

[4]  Zhiwei Lin,et al.  Layered infill area generation from triply periodic minimal surfaces for additive manufacturing , 2019, Comput. Aided Des..

[5]  Wangyu Liu,et al.  A novel parameterized digital-mask generation method for projection stereolithography in tissue engineering , 2018, Rapid Prototyping Journal.

[6]  David W. Rosen,et al.  Design for Additive Manufacturing , 2015, Additive Manufacturing Technologies.

[7]  Amit Bandyopadhyay,et al.  Starch-Hydroxyapatite Composite Bone Scaffold Fabrication Utilizing a Slurry Extrusion-Based Solid Freeform Fabricator. , 2018, Additive manufacturing.

[8]  Wenping Wang,et al.  Feature-preserving T-mesh construction using skeleton-based polycubes , 2015, Comput. Aided Des..

[9]  Bin Li,et al.  Direct slicing of T-spline surfaces for additive manufacturing , 2018 .

[10]  Zheng Gu,et al.  Fabrication of PLLA/β-TCP nanocomposite scaffolds with hierarchical porosity for bone tissue engineering. , 2014, International journal of biological macromolecules.

[11]  J. Hope,et al.  Is there a decline in bovine spongiform encephalopathy cases born after reinforced feed bans? A modelling study in EU member states , 2017, Epidemiology and Infection.

[12]  C. Broeckhoven,et al.  Beautiful and Functional: A Review of Biomimetic Design in Additive Manufacturing , 2019, Additive Manufacturing.

[13]  Jianzhong Fu,et al.  A review of the design methods of complex topology structures for 3D printing , 2018, Visual Computing for Industry, Biomedicine, and Art.

[14]  R. Zuo,et al.  Fractal/multifractal modeling of geochemical data: A review , 2016 .

[15]  S M Giannitelli,et al.  Current trends in the design of scaffolds for computer-aided tissue engineering. , 2014, Acta biomaterialia.

[16]  Lars-Erik Rännar,et al.  Fabrication of multiple-layered gradient cellular metal scaffold via electron beam melting for segmental bone reconstruction , 2017 .

[17]  Rashid K. Abu Al-Rub,et al.  Topology-mechanical property relationship of 3D printed strut, skeletal, and sheet based periodic metallic cellular materials , 2018 .

[18]  F. Dehghani,et al.  Formation of porous biodegradable scaffolds based on poly(propylene carbonate) using gas foaming technology. , 2019, Materials science & engineering. C, Materials for biological applications.

[19]  Neil Eisenstein,et al.  Clinical, industrial, and research perspectives on powder bed fusion additively manufactured metal implants , 2019, Additive Manufacturing.

[20]  Ibrahim T. Ozbolat,et al.  Designing heterogeneous porous tissue scaffolds for additive manufacturing processes , 2013, Comput. Aided Des..

[21]  Charlie C. L. Wang,et al.  Intersection-Free and Topologically Faithful Slicing of Implicit Solid , 2013, J. Comput. Inf. Sci. Eng..

[22]  S. Bose,et al.  Effects of pore distribution and chemistry on physical, mechanical, and biological properties of tricalcium phosphate scaffolds by binder-jet 3D printing , 2018, Additive Manufacturing.

[23]  T. Hughes,et al.  Local refinement of analysis-suitable T-splines , 2012 .

[24]  D. Yoo,et al.  Heterogeneous minimal surface porous scaffold design using the distance field and radial basis functions. , 2012, Medical engineering & physics.

[25]  Dawei Li,et al.  Optimal design and modeling of gyroid-based functionally graded cellular structures for additive manufacturing , 2018, Comput. Aided Des..

[26]  Abbas S. Milani,et al.  Longitudinal and radial permeability analysis of additively manufactured porous scaffolds: Effect of pore shape and porosity , 2017 .

[27]  Clemens A van Blitterswijk,et al.  Effects of the architecture of tissue engineering scaffolds on cell seeding and culturing. , 2010, Acta biomaterialia.

[28]  Klaus Mecke,et al.  Minimal surface scaffold designs for tissue engineering. , 2011, Biomaterials.

[29]  Dong-Jin Yoo,et al.  Computer-aided porous scaffold design for tissue engineering using triply periodic minimal surfaces , 2011 .

[30]  Philip J. Withers,et al.  The effect of density and feature size on mechanical properties of isostructural metallic foams produced by additive manufacturing , 2015 .

[31]  Chengtie Wu,et al.  Hierarchically porous nagelschmidtite bioceramic-silk scaffolds for bone tissue engineering. , 2015, Journal of materials chemistry. B.

[32]  Wei Xu,et al.  Topological design and additive manufacturing of porous metals for bone scaffolds and orthopaedic implants: A review. , 2016, Biomaterials.

[33]  Bin Li,et al.  Closed T-Spline Surface Reconstruction from Medical Image Data , 2018 .

[34]  D. Yoo.  New paradigms in hierarchical porous scaffold design for tissue engineering. , 2013, Materials science & engineering. C, Materials for biological applications.

[35]  D. McNally,et al.  Computational mechanical characterization of geometrically transformed Schwarz P lattice tissue scaffolds fabricated via two photon polymerization (2PP) , 2019, Additive Manufacturing.

[36]  Gianpaolo Savio,et al.  Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review , 2018, Applied bionics and biomechanics.

[37]  Dinesh Manocha,et al.  GPU-based offset surface computation using point samples , 2013, Comput. Aided Des..

[38]  Yimin Wang,et al.  Curvature-guided adaptive TT-spline surface fitting , 2013, Comput. Aided Des..

[39]  Gershon Elber,et al.  Hierarchical, random and bifurcation tiling with heterogeneity in micro-structures construction via functional composition , 2018, Comput. Aided Des..

[40]  Jerry Ying Hsi Fuh,et al.  Triply Periodic Minimal Surfaces Sheet Scaffolds for Tissue Engineering Applications: An Optimization Approach toward Biomimetic Scaffold Design. , 2018, ACS applied bio materials.

[41]  Scott J. Hollister,et al.  Erratum: Porous scaffold design for tissue engineering , 2006 .

[42]  Amir A Zadpoor,et al.  Bone tissue regeneration: the role of scaffold geometry. , 2015, Biomaterials science.

[43]  K. Wilson,et al.  Hierarchical porous materials: catalytic applications. , 2013, Chemical Society reviews.

[44]  Dong-Jin Yoo,et al.  Heterogeneous porous scaffold design for tissue engineering using triply periodic minimal surfaces , 2012 .

[45]  Zongsong Gan,et al.  Biomimetic gyroid nanostructures exceeding their natural origins , 2016, Science Advances.

[46]  O. Harrysson,et al.  Electron beam melted scaffolds for orthopedic applications , 2017 .

[47]  Peter Fratzl,et al.  The effect of geometry on three-dimensional tissue growth , 2008, Journal of The Royal Society Interface.

[48]  Guanjun Wang,et al.  Design and Compressive Behavior of Controllable Irregular Porous Scaffolds: Based on Voronoi-Tessellation and for Additive Manufacturing. , 2018, ACS biomaterials science & engineering.

[49]  Martin Caffrey,et al.  Nano-volume plates with excellent optical properties for fast, inexpensive crystallization screening of membrane proteins , 2003 .

[50]  Charlie C. L. Wang,et al.  Self-supporting rhombic infill structures for additive manufacturing , 2016, Comput. Aided Des..

[51]  Lu Han,et al.  An Overview of Materials with Triply Periodic Minimal Surfaces and Related Geometry: From Biological Structures to Self‐Assembled Systems , 2018, Advanced materials.

[52]  W. Yeong,et al.  Metallic powder-bed based 3D printing of cellular scaffolds for orthopaedic implants: A state-of-the-art review on manufacturing, topological design, mechanical properties and biocompatibility. , 2017, Materials science & engineering. C, Materials for biological applications.

[53]  Jiawei Feng,et al.  Porous scaffold design by solid T-splines and triply periodic minimal surfaces , 2018, Computer Methods in Applied Mechanics and Engineering.

[54]  Charlie C. L. Wang,et al.  Algorithms for Layered Manufacturing in Image Space , 2014 .

[55]  S. Hollister.  Porous scaffold design for tissue engineering , 2005, Nature materials.

[56]  W E Bolch,et al.  Marching cube algorithm: review and trilinear interpolation adaptation for image-based dosimetric models. , 2003, Computerized medical imaging and graphics : the official journal of the Computerized Medical Imaging Society.

[57]  Bahattin Koc,et al.  Functionally heterogeneous porous scaffold design for tissue engineering , 2012, Comput. Aided Des..

[58]  Charlie C. L. Wang,et al.  The status, challenges, and future of additive manufacturing in engineering , 2015, Comput. Aided Des..

[59]  M. Marzec,et al.  A review: fabrication of porous polyurethane scaffolds. , 2015, Materials science & engineering. C, Materials for biological applications.

[60]  Kuntao Zhou,et al.  Effective method for multi-scale gradient porous scaffold design and fabrication. , 2014, Materials science & engineering. C, Materials for biological applications.

[61]  J. Czernuszka,et al.  The need for hierarchical scaffolds in bone tissue engineering , 2013 .