fast casters - formal design review march 2, 2006 rene chen byron hsu kimberly kam kelsey...
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Fast Casters - Formal Design Fast Casters - Formal Design ReviewReview
March 2, 2006March 2, 2006
Rene ChenRene Chen
Byron HsuByron Hsu
Kimberly KamKimberly Kam
Kelsey VandermeulenKelsey Vandermeulen
Lisa WitmerLisa Witmer
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Brief UpdateBrief Update
Speed Skate BladeSpeed Skate Blade Titanium blade will likely shatterTitanium blade will likely shatter
Final DecisionFinal Decision 3D printed bone scaffold3D printed bone scaffold
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Current ScaffoldsCurrent Scaffolds
Jim Serdy 12/28/04
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Project GoalProject Goal
Improve the mechanical properties of Improve the mechanical properties of bone scaffolds through optimizing bone scaffolds through optimizing the composition of the printing the composition of the printing powderpowder
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Desired Scaffold Properties:Desired Scaffold Properties:BiocompatibilityBiocompatibility
Materials candidatesMaterials candidates PLGA – poly lactic acid-co-glycolic acidPLGA – poly lactic acid-co-glycolic acid PCL – poly caprolactone PCL – poly caprolactone TCP – tricalcium phosphateTCP – tricalcium phosphate HA – hydroxyapatiteHA – hydroxyapatite
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Desired Scaffold Properties: Desired Scaffold Properties: MechanicalMechanical
Elastic modulus varies with Elastic modulus varies with age and locationage and location Target Range:Target Range:
10-20 GPa10-20 GPa
Uniaxial compression and Uniaxial compression and tension three orthogonal tension three orthogonal directionsdirections
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Desired Scaffold Properties:Desired Scaffold Properties:ArchitectureArchitecture
Channel GeometryChannel Geometry 400-1200 um400-1200 um Waffle structureWaffle structure
Cell and vascular Cell and vascular in-growthin-growth
Jim Serdy 12/28/04
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Current MIT ResearchCurrent MIT Research
Jim Serdy Jim Serdy Lab of Manufacturing and Lab of Manufacturing and Productivity Productivity Has been working with bone scaffolds Has been working with bone scaffolds MGH and Cleveland ClinicMGH and Cleveland Clinic
Agreed to supervise our work in his labAgreed to supervise our work in his lab Our work will explore areas of his Our work will explore areas of his
interest as wellinterest as well
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Alpha 3D PrinterAlpha 3D Printer Laboratory of Manufacturing and Laboratory of Manufacturing and
ProductivityProductivity
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Jim Serdy’s ResearchJim Serdy’s Research PatentPatent
PLGA + PCL + sucrose + lactose + PLGA + PCL + sucrose + lactose + waterwater
Dissolves sucrose and lactose to form poresDissolves sucrose and lactose to form pores Vacuum + chloroform to bind polymerVacuum + chloroform to bind polymer
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ImprovementsImprovements
Bone scaffold is too soft/compliantBone scaffold is too soft/compliant Increase the stiffness by Increase the stiffness by
incorporation of higher TCP incorporation of higher TCP concentrataionsconcentrataions
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Jaw Bone ScaffoldJaw Bone Scaffold
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RisksRisks Risk 1: Time LimitationsRisk 1: Time Limitations
Formulation of the powder can be a very complicated Formulation of the powder can be a very complicated process by itselfprocess by itself
Iteration time of powder composition-printing-visual and Iteration time of powder composition-printing-visual and mechanical testingmechanical testing
Planned 4 weeks per cyclePlanned 4 weeks per cycle
Risk 2: 3D printer reliabilityRisk 2: 3D printer reliability Trouble shooting the 3D printer is time consumingTrouble shooting the 3D printer is time consuming Single compatible machineSingle compatible machine While trouble shooting the 3D printer, we can be While trouble shooting the 3D printer, we can be
formulating the powder and working on the jaw bone formulating the powder and working on the jaw bone through CAD, etc.through CAD, etc.
Work ahead of time, allow buffer timeWork ahead of time, allow buffer time
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Key Decision PointsKey Decision Points
Desired mechanical propertiesDesired mechanical properties Strategies of approaching desired Strategies of approaching desired
propertiesproperties Powder compositions to testPowder compositions to test Balancing stiffness and density Balancing stiffness and density
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Materials and CostsMaterials and CostsProductProduct Molecular Molecular
FormulaFormulaMolecular Molecular
WeightWeightCAS CAS
NumberNumberCompanyCompany Product #Product # Price Price
(USD)(USD)Available to Available to
shipship
Hydroxyapatite Hydroxyapatite (HA)(HA)
CaCa55(PO(PO
44))33OHOH 502.31502.31 1306-06-51306-06-5 Sigma-Sigma-AldrichAldrich
289396-25G289396-25G 57.7057.70 02.03.200602.03.2006
289396-100G289396-100G 210.40210.40 02.03.200602.03.2006
Poly(lactic-co-Poly(lactic-co-glycolic acid) glycolic acid)
(PLGA)(PLGA)
Very Very expensiveexpensive
Polycaprolactone Polycaprolactone (PCL)(PCL)
((CC66HH1010OO22))nn ~65,000~65,000 24980-41-424980-41-4 Sigma-Sigma-AldrichAldrich
181609-250G181609-250G 75.1075.10 03.03.200603.03.2006
181609-500G181609-500G 131.50131.50 Date not availableDate not available
Poly(vinyl Poly(vinyl alcohol)alcohol)(PVA)(PVA)
[-CH[-CH22CHOH-]CHOH-]nn 13,000-13,000-23,00023,000
9002-89-59002-89-5 Sigma-Sigma-AldrichAldrich
363170-25G363170-25G 27.0027.00 03.03.200603.03.2006
363170-1KG363170-1KG 94.5094.50 03.03.200603.03.2006
Tricalcium Tricalcium phosphate phosphate
(TCP)(TCP)
CaCa33(PO(PO
44))22 310.18310.18 7758-87-47758-87-4 Sigma-Sigma-AldrichAldrich
50553-1G-F50553-1G-F 58.2058.20 Date not availableDate not available
50553-10G-F50553-10G-F 305.00305.00 02.03.200602.03.2006
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Project TimelineProject Timeline
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ResourcesResources
3D Printer3D Printer: James Serdy’s lab : James Serdy’s lab
Room 35-011Room 35-011
Laboratory for Manufacturing and Laboratory for Manufacturing and ProductivityProductivity
Workstations for using Workstations for using SolidworksSolidworks and and AnsysAnsys: :
Room 8-241 Room 8-241
SEMSEM: Room 13-4139?: Room 13-4139?
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Thank YouThank You
Questions?Questions?