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?