Additive manufacturing (AM) of medical devices such as orthopedic implants and hearing aids is highly attractive because of the potential of AM to match the complex form and mechanics of individual human bodies. Externally worn and implantable tissue-support devices, such as ankle or knee braces, and hernia repair mesh, offer a new opportunity for AM to mimic tissuelike mechanics and improve both patient outcomes and comfort. Here, it is demonstrated how explicit programming of the toolpath in an extrusion AM process can enable new, flexible mesh materials having digitally tailored mechanical properties and geometry. Meshes are fabricated by extrusion of thermoplastics, optionally with continuous fiber reinforcement, using a continuous toolpath that tailors the elasticity of unit cells of the mesh via incorporation of slack and modulation of filament-filament bonding. It is shown how the tensile mesh mechanics can be engineered to match the nonlinear response of muscle. An ankle brace with directionally specific inversion stiffness arising from embedded mesh is validated, and further concepts for 3D mesh devices are prototyped.

No abstract

No abstract

Explicit toolpath programming in an additive manufacturing process can enable flexible mesh materials with digitally tailored mechanics and geometry. In article number 1901815, Sebastian W. Pattinson, A. John Hart, and co‐workers demonstrate that tensile mesh mechanics can be engineered to match the nonlinear response of the muscle. An ankle brace with directionally specific inversion stiffness is validated, and further concepts for 3D mesh devices are prototyped.

No abstract