Three Dimensional Scaffold Direct Writer for Fabricating Fiber-Reinforced Materials

Three-Dimensional Scaffold Direct Writer
For Fabricating Fiber-Reinforced
Materials
Rohan Rath
Industrial & Systems Engineering

Unit Name
Optional Presentation Title
Objective
Design an automated machine for fabricating fiber-
reinforced materials: 3D Scaffold Direct Writer (SDW)
Establish a manufacturing process for fabricating
continuous-fiber tissue engineered scaffolds
Student Technical Paper Competition
May 31, 2015

Unit Name
Background
May 31, 2015
(d) Synthetic meniscus [4]
(a) Synthetic ear [15]
(c) Electrospun skin [17]
(b) Printed heart [16]
Customizable biomaterials are
feasible raw material
Greater customization through
flexible manufacturing is necessary
Engineered tissue + flexible
manufacturing ⇒ Bio-manufacturing

Unit Name
Optional Presentation TitleStudent Technical Paper Competition
May 31, 2015
Meniscal injuries: 1.4 million surgical interventions
annually (US & EU)
Tissue supply chain: limited by donation (allograft)
Menisci are not self-healing
Background

Unit Name
May 31, 2015
Background
Autograft, collagen meniscus implant (CMI)
CMI + filament matrix (a) = RWJ implant (c)
RWJ implant + SDW = Meniscus Bio-manufacturing
(a) Internal filament matrix [4] (c) Freeze-dried final product [4](b) Manual substrate

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May 31, 2015
MarkForged MarkOne [1] Microfluidic Direct Writer [3]
Current Mass Customization Technology

Unit Name
May 31, 2015
(b) Prototype
collagen tool
(a) Writing tool
(c) 80/20
frame
(f) XY motion
platform
(e) Writing
substrate(d) Z axis
ball screw
SDW System
SDW = Writing Tool + Writing Substrate + XY Platform

Unit Name
(g) Spool pinch
(a) Spring housing
(e) Spring
(d) Fiber spool
(between frames)
(b) Laser-cut
acrylic frames
(f) Syringe
needle
(c) Swivel
spring anchors
May 31, 2015
SDW Subsystem: Writing Tool
Replaces the human hand
Pinch allows variable settings

Unit Name
May 31, 2015
Re-usable
Vertically oriented pins
One pin diameter
Three discrete layouts
Pin pre-configured scaffold support structure
SDW Subsystem: Writing Substrate
(a) ~3 [mm] pin
(c) Removable,
pin-inserted
substrate
(d) XY mount plate
(b) Reinforcing
filament

Unit Name
May 31, 2015
SDW System

Unit Name
May 31, 2015
(a) Present pin
top vertex:
SDW tool
starting
position
Tool Path Terminology

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May 31, 2015
(b) Ending pin
top vertex:
SDW tool
ending
position
(a) Present pin
top vertex:
SDW tool
starting
position

Unit Name
May 31, 2015
(c) Traces of tool positions
(a) Present pin
top vertex:
SDW tool
starting
position
(b) Ending pin
top vertex:
SDW tool
ending
position

Unit Name
(d) Intermediate
filament positions
May 31, 2015
(a) Present pin
top vertex:
SDW tool
starting
position
(b) Ending pin
top vertex:
SDW tool
ending
position

Unit Name
May 31, 2015
(d) Intermediate
filament positions
(e) Ending pin
bottom vertex
(a) Present pin
top vertex:
SDW tool
starting
position
(b) Ending pin
top vertex:
SDW tool
ending
position

Unit Name
May 31, 2015
(d) Intermediate
filament positions
(f) Permanent filament trajectory: 𝑨 𝟏 (c) Traces of tool positions
(e) Ending pin
bottom vertex
(a) Present pin
top vertex:
SDW tool
starting
position
(b) Ending pin
top vertex:
SDW tool
ending
position

Unit Name
May 31, 2015
(b) Layer two subgraph: 𝑨 𝟐(a) Layer one subgraph: 𝑨 𝟏
(c) Layer three subgraph: 𝑨 𝟑
“Stacked” 3D
subscaffold: the
filament matrix between
any pair of pins has at
most three distinct layers

Unit Name
May 31, 2015

Unit Name
May 31, 2015
𝑨 𝟏 Red
Partial 𝑾 𝒑=𝟏𝟐 subscaffold of
subgraphs 𝑨 𝟏- 𝑨 𝟔
 Subgraph layers 𝐴1 𝑡𝑜 𝐴𝑖 = sets of
permanent filament trajectories
 “Stacking” subgraphs defines a 3D
subscaffold, 𝑊𝑝, 𝑤𝑖𝑡ℎ 𝑖 ∈ (1, 𝑝 + 2)
 Subscaffold sequence defines the
3D scaffold “S”; explicitly:
 𝐴6 = { 𝑥 𝟏,1, 𝑥 𝟐,1 , (𝑥 𝟐,1, 𝑦 𝟐,3),(𝑦 𝟐,3,
𝑦 𝟏𝟎,4), (𝑦 𝟏𝟎,3, 𝑦 𝟐𝟒,3), 𝑦 𝟐𝟒,3, 𝑥 𝟑,3 , (𝑥 𝟑,3,
𝑥 𝟒,3)}
 𝑊12 = 𝐴1 + 𝐴2 + ⋯ + 𝑨 𝟔 + ⋯ + 𝐴14
 𝑆 = {𝑊1, 𝑾 𝟏𝟐, 𝑊10, 𝑾 𝟏𝟐 … , 𝑊4, 𝑊1}

Unit Name
May 31, 2015
 𝐴6 = { 𝑥 𝟏,1, 𝑥 𝟐,1 , (𝑥 𝟐,1, 𝑦 𝟐,3),(𝑦 𝟐,3,
𝑦 𝟏𝟎,4), (𝑦 𝟏𝟎,3, 𝑦 𝟐𝟒,3), 𝑦 𝟐𝟒,3, 𝑥 𝟑,3 , (𝑥 𝟑,3,
𝑥 𝟒,3)}
 𝑊12 = 𝐴1 + 𝐴2 + ⋯ + 𝑨 𝟔 + ⋯ + 𝐴14
 𝑆 = {𝑊1, 𝑾 𝟏𝟐, 𝑊10, 𝑾 𝟏𝟐 … , 𝑊4, 𝑊1}
𝑨 𝟏 Red
𝑨 𝟐 Orange

Unit Name
May 31, 2015
 𝐴6 = { 𝑥 𝟏,1, 𝑥 𝟐,1 , (𝑥 𝟐,1, 𝑦 𝟐,3),(𝑦 𝟐,3,
𝑦 𝟏𝟎,4), (𝑦 𝟏𝟎,3, 𝑦 𝟐𝟒,3), 𝑦 𝟐𝟒,3, 𝑥 𝟑,3 , (𝑥 𝟑,3,
𝑥 𝟒,3)}
 𝑊12 = 𝐴1 + 𝐴2 + ⋯ + 𝑨 𝟔 + ⋯ + 𝐴14
 𝑆 = {𝑊1, 𝑾 𝟏𝟐, 𝑊10, 𝑾 𝟏𝟐 … , 𝑊4, 𝑊1}
𝑨 𝟏 Red
𝑨 𝟐 Orange
𝑨 𝟑 Purple

Unit Name
May 31, 2015
 𝐴6 = { 𝑥 𝟏,1, 𝑥 𝟐,1 , (𝑥 𝟐,1, 𝑦 𝟐,3),(𝑦 𝟐,3,
𝑦 𝟏𝟎,4), (𝑦 𝟏𝟎,3, 𝑦 𝟐𝟒,3), 𝑦 𝟐𝟒,3, 𝑥 𝟑,3 , (𝑥 𝟑,3,
𝑥 𝟒,3)}
 𝑊12 = 𝐴1 + 𝐴2 + ⋯ + 𝑨 𝟔 + ⋯ + 𝐴14
 𝑆 = {𝑊1, 𝑾 𝟏𝟐, 𝑊10, 𝑾 𝟏𝟐 … , 𝑊4, 𝑊1}
𝑨 𝟏 Red
𝑨 𝟐 Orange
𝑨 𝟑 Purple
𝑨 𝟒 Green

Unit Name
May 31, 2015
 𝐴6 = { 𝑥 𝟏,1, 𝑥 𝟐,1 , (𝑥 𝟐,1, 𝑦 𝟐,3),(𝑦 𝟐,3,
𝑦 𝟏𝟎,4), (𝑦 𝟏𝟎,3, 𝑦 𝟐𝟒,3), 𝑦 𝟐𝟒,3, 𝑥 𝟑,3 , (𝑥 𝟑,3,
𝑥 𝟒,3)}
 𝑊12 = 𝐴1 + 𝐴2 + ⋯ + 𝑨 𝟔 + ⋯ + 𝐴14
 𝑆 = {𝑊1, 𝑾 𝟏𝟐, 𝑊10, 𝑾 𝟏𝟐 … , 𝑊4, 𝑊1}
𝑨 𝟏 Red
𝑨 𝟐 Orange
𝑨 𝟑 Purple
𝑨 𝟒 Green
𝑨 𝟓 Blue

Unit Name
May 31, 2015
 𝐴6 = { 𝑥 𝟏,1, 𝑥 𝟐,1 , (𝑥 𝟐,1, 𝑦 𝟐,3),(𝑦 𝟐,3,
𝑦 𝟏𝟎,4), (𝑦 𝟏𝟎,3, 𝑦 𝟐𝟒,3), 𝑦 𝟐𝟒,3, 𝑥 𝟑,3 , (𝑥 𝟑,3,
𝑥 𝟒,3)}
 𝑊12 = 𝐴1 + 𝐴2 + ⋯ + 𝑨 𝟔 + ⋯ + 𝐴14
 𝑆 = {𝑊1, 𝑾 𝟏𝟐, 𝑊10, 𝑾 𝟏𝟐 … , 𝑊4, 𝑊1}
𝑨 𝟏 Red
𝑨 𝟐 Orange
𝑨 𝟑 Purple
𝑨 𝟒 Green
𝑨 𝟓 Blue
𝑨 𝟔 Black

Unit Name
May 31, 2015
3D subscaffolds: unique constant-tension
filament matrices that define implant geometry
http://patentimages.storage.googleapis.com/US20140031933A1/US20140031933A1-20140130-D00009.png
𝑾 𝟏: 𝐴1- 𝐴3 𝑾 𝟒: 𝐴1- 𝐴6 𝑾 𝟔: 𝐴1- 𝐴8
𝑾 𝟖: 𝐴1- 𝐴10 𝑾 𝟏𝟎: 𝐴1- 𝐴12 𝑾 𝟏𝟐: 𝐴1- 𝐴14

Unit Name
May 31, 2015
System Complexity: 3D Stacking

Unit Name
Manual versus SDW Fabrication
May 31, 2015
 Non-stop, no collision direct writing
 Reduces variability and human error
 Creates acceptable FDA process
 On-line optical quality control feasible
(a) Manual product [4] (b) SDW product

Unit Name
May 31, 2015
Business Process: Current
Random
donor
death
Disease
screening
Tissue
removal
surgery
Bio-
preserving
transport
Storage
(FDA
regulated)
Bio-
preserving
delivery
Transplant/arthroscopy
surgery ($11900 US
avg.)
JIT organ
matching
(limited supply)
Extensive
patient
screening &
assessment

Unit Name
May 31, 2015
Business Process: Proposed
In-house, FDA
approved,
custom implant
manufacture
($1k - $2k)
Implant
Surgery
($3k - $5k)
Biomaterial
batch
production
Extensive
patient
screening &
assessment

Unit Name
May 31, 2015
Impact on Business Process
 Relies on organ donation
 Two surgeries
 Live tissue – possibility of
disease transmission
 Complex transport logistics
 Size-matching complexities
 Unbound biomaterial supply
 One surgery
 Synthetic tissue – no
possibility of disease
transmission
 In-house inventory – no
transportation needed
 Size-customizable implants
Current Proposed

Unit Name
Conclusion
May 31, 2015
Create an efficient and controllable manufacturing
process for fiber-reinforced scaffolds
Utilize IE knowledge to build a machine, as a part of
a design course, within budget, time and resource
limitations
Introduce new mass customization technology in a
focused area of implant tissue engineering

Unit Name
Project members : J. Levy, K. MacKinnon, D. Vas
Advising professors: E. Elsayed, K. Li
RWJ Orthopedics: M. Dunn, C. Gatt, J. Patel
Rutgers Makerspace laboratory: R. Anderson
Student technical paper competition sponsor: John Deere
Funding Sources:
 Rutgers ISE: M. Jafari
 Rutgers SOE: I. Rosen
 IIE South Jersey Delaware Valley: J. McGowan
 ISERC stipend: IIE National
 NSF student travel grant: S. Cetinkaya, J. Ryan
Acknowledgements
May 31, 2015

Unit Name
Reference
May 31, 2015
[1] MarkOne". MarkForged. https://markforged.com/mark-one/
[2] Moutos, F. T., Freed, L. E., Guilak, F. (2007). A biomimetic three dimensional woven com-
posite scaold for functional tissue engineering of cartilage. Nature Materials, 6(2), 162-167.
[3] Ghorbanian, S., Qasaimeh M. A., Akbar, M., Tamayol, A., Juncker, D. (2014). Microfluidic
Direct Writer with Integrated Declogging Mechanism for Fabricating Cell-Laden Hydrogel
Constructs. Biomedical Microdevices, 16(3), 387-395.
[4] Balint, E., Gatt C., J., Dunn M. G..(2011). Design and mechanical evaluation of a novel
fiber- reinforced scaffold for meniscus replacement. Orthopaedic Research Laboratories.
[5] Shybut, T., Strauss, E. J. (2011).Surgical Management of Meniscal Tears. Bulletin of the
NYU Hospital for Joint Diseases, 69(1), 56.
[6] Newman, A. P., Daniels, A. U., Burks R. T. (1993).Principles and Decision Making in Menis-
cal Surgery. Arthroscopy Association of North America. The Journal of Arthroscopic and
Related Surgery, 9(1), 33-51.

Unit Name
Reference
May 31, 2015
[7] Tovar, N., Bourke, S., Jae, M., Murthy S. N., Kohn, J., Gatt, C., Dunn, M. G. (2010).
A Comparison of Degradable Synthetic Polymer Fibers for Anterior Cruciate Ligament
Reconstruction. J. Biomedical Material Research Association, 93(2), 738-747. doi:
[8] Tamayol, A., Akbari, M., Annabi, N., Paul, A., Khademhosseini A., Juncker, D. (2013) Fiber-
Based Tissue Engineering: Progress, Challenges, and Opportunities.Biotechnol Adv., 31(5),
669-687. doi: 10.1016/j.biotechadv.2012.11.007.
[9] Hong, Y.,Gong, Y., Gao, C., Shen, J. (2006). Collagen-coated polylactide
microcarriers/chitosan hydrogel composite: Injectable scaffold for cartilage regeneration.
Wiley InterScience (www.interscience.wiley.com). doi: 10.1002/jbm.a.31603.
[10] Robert Jan Peter van der Wal.(2009) Long-term Clinical Outcome of Open Meniscal Al-
lograft Transplantation. American Journal of Sports Medicine. November 2009. 37(11). Pp.
2134-2139.
[11] Sun, W. (2013).Bio-3D Printing.National Science Foundation Workshop on Frontiers of
Additive Manufacturing Research and Education.

Unit Name
Reference
May 31, 2015
[12] Akbari, M., Tamayol, A., Laforte, V., Annabi, N., Khademhosseini A., Juncker D. (2013)
Continuous Manufacture of Robust Living Fibers That Withstand Common Textile
Processing for Tissue Engineering Applications. International Conference on Miniaturized
Systems for Chemistry and Life Sciences.
[13] Richards, D. J., Tan, Y., Jia, J., Yao, H., Mei Y. (2013).3D Printing for Tissue Engineering.
Israel Journal of Chemistry, 53, 805-814.
[14] Nielsen AB, Yde J. (1991). Epidemiology of acute knee injuries: a prospective hospital
investigation. J Trauma, 31(12), 1644-1648.
[15] http://dailynewsdig.com/wp-content/uploads/2013/07/bionic-ear.jpg
[16] https://www.asme.org/getmedia/f8c45f03-a1f7-4e94-8c7d-8772ff0b8c69/Creating-Valve-
Tissue-Using-3D-Bioprinting_02.jpg.aspx?width=340
[17] https://s-media-cache-
k0.pinimg.com/236x/08/d8/35/08d835697d6ed5fe1cbd9c03972bb74f.jpg

Unit Name
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May 31, 2015

Three Dimensional Scaffold Direct Writer for Fabricating Fiber-Reinforced Materials

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