3D printed patient-specific meshes made of poly (L-lactide-co-D, L-lactide) and β-TCP for guided bone regeneration.

The available meshes for guided bone regeneration are often made of metal and have to be removed by a second surgery after successful bone healing. With bioresorbable materials, such as polymers, a second surgery to remove the implant can be avoided. By combining bioresorbable materials with 3D printing technology, patient-specific meshes for the maxillofacial area can be produced. Arburg Plastic Freeforming is an innovative 3D printing technology that is finding its way into the medical field. In this study, different approaches were used to optimise the parameters for the bioresorbable polymer poly(L-lactide-co-D, L-lactide) with 30% β-tricalcium phosphate (PLDLLA/β-TCP) on the Arburg Freeformer. By adjusting the parameters drop aspect ratio (DAR), discharge rate (DR), droplet overlap and chamber temperature (Tc), the mechanical stability and print quality of the 3D-printed parts could be increased. Other parameters were investigated but remained unchanged. For horizontally printed samples, an increase in flexural modulus of about 0.4GPa and an increase in flexural strength of 25MPa could be achieved compared to the old parameters. Overall, a flexural modulus of 3.54GPa ± 0.17 and flexural strength of 87.1MPa ± 2.37 were achieved. Tensile tests showed a tensile modulus of 201MPa ± 18.5 and a tensile strength of 47.1MPa ± 0.86. The overall print quality was checked using surface images, which showed a regular print pattern with no gaps between the layers compared to the old parameters. Within the scope of this work, patient-specific meshes were designed and produced with the newly found parameters. With the parameter settings DAR 1.19, DR 65%, overlap 30% and Tc 85°C for PLDLLA/β-TCP, it was possible to produce meshes for the orbital and mandibular area with good quality and accuracy of fit on the Arburg Freeformer.