Mitigation of tracheobronchomalacia with 3D-printed personalized medical devices in pediatric patients

Patient-specific, image-based design coupled with 3D biomaterial printing produced personalized implants for treatment of collapsed airways in patients with tracheobronchomalacia. Printing in 4D: Personalized implants The 3D printing revolution is in full swing, with frequent reports of printed kidneys and jaws, dolls and cars, food, and body armor. The new challenge is to make 3D materials evolve in the fourth dimension: time. Such “4D” materials could change in response to temperature, light, or even stress, making them adaptable and enduring. In pediatric medicine, 4D implants become particularly relevant; as the patient grows, so, too, should the material. Morrison et al. used 3D printing technology with a safe, bioresorbable polymer blend to create splints for three pediatric patients with tracheobronchomalacia (TBM)—a condition of excessive collapse of the airways during normal breathing. Currently available fixed-size implants can migrate and require frequent resizing. Thus, the authors used imaging and computational models to design the splints for each TBM patient’s individual geometries, structuring the implants to accommodate airway growth and prevent external compression over a period of time, before being resorbed by the body. In all three patients (one with two airways splinted), the 4D devices were implanted without issue. All four implants were stable and functional after 1 month, and one implant has remained in place, keeping the airway open for over 3 years. This pilot trial demonstrates that the fourth dimension is a reality for 3D-printed materials, and with continued human studies, 4D biomaterials promise to change the way we envision the next generation of regenerative medicine. Three-dimensional (3D) printing offers the potential for rapid customization of medical devices. The advent of 3D-printable biomaterials has created the potential for device control in the fourth dimension: 3D-printed objects that exhibit a designed shape change under tissue growth and resorption conditions over time. Tracheobronchomalacia (TBM) is a condition of excessive collapse of the airways during respiration that can lead to life-threatening cardiopulmonary arrests. We demonstrate the successful application of 3D printing technology to produce a personalized medical device for treatment of TBM, designed to accommodate airway growth while preventing external compression over a predetermined time period before bioresorption. We implanted patient-specific 3D-printed external airway splints in three infants with severe TBM. At the time of publication, these infants no longer exhibited life-threatening airway disease and had demonstrated resolution of both pulmonary and extrapulmonary complications of their TBM. Long-term data show continued growth of the primary airways. This process has broad application for medical manufacturing of patient-specific 3D-printed devices that adjust to tissue growth through designed mechanical and degradation behaviors over time.