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Keywords: Modern 3D printing of implantable devices provides an important opportunity for the development of person
Silicones alized implants with good anatomical fit. Nevertheless, 3D printing of silicone has been challenging and the
Mechanical properties recent advances in technology are provided by the systems which can print medical grade silicone via extrusion.
In vitro
However, the potential impacts of the 3D printing process of silicone on its biomechanical properties has not
In vivo
Biocompatibility
been studied in sufficient detail. Therefore, the present study compares 3D printed and moulded silicone
Implants structures for their cytotoxicity, surface roughness, biomechanical properties, and in vivo tissue reaction. The 3D
printing process creates increased nanoscale roughness and noticeably changes microscale topography. Neither
the presence of these features nor the differences in processes were found to result in an increase in cytotoxicity
or tissue reaction for 3D printed structures, exhibiting limited inflammatory reaction and cell viability above the
threshold values. On the contrary, the biomechanical properties have demonstrated significant differences in
static and dynamic conditions, and in thermal expansion. Our results demonstrate that 3D printing can be used
for establishing a better biomechanical microenvironment for the surrounding tissue of the implant particularly
for fragile soft tissue like epithelial mucosa without having any negative effect on the cytotoxicity or in vivo
reaction to silicone. For engineering of the implants, however, one must consider the differences in mechanical
properties to result in correct and personalized geometry and proper physical interaction with tissues.
1. Introduction The stent might move from its position or even come out of the patient
entirely. Moreover, the mucosa of the upper respiratory tract is highly
There is a growing trend to use 3D printing as the manufacturing fragile and any excessive pressure applied to the mucosa by stents would
method for medical devices enabling their personalization (Vrana et al., lead to an adverse immune reaction and necrosis. In addition to this,
2020; Jammalamadaka and Tappa, 2018; Nagarajan et al., 2018; some patients would have unconventional anatomical features due to
Kacarevic et al., 2018; DiMarzio et al., 2020). Medical grade silicone is trauma or surgical resection to which normal stents would apply addi
widely used in health care (Sittel, 2009; Emre et al., 2005) and it can be tional pressure and risk of damage. This problem can be prevented by
processed using 3D printing (Jammalamadaka and Tappa, 2018; creating custom devices with a better fit, which can be achieved with a
Kacarevic et al., 2018). An example of a medical device requiring a high 3D printing technology. However, beyond the anatomical fit of the
personalization is stents used in the upper respiratory tract, whose stents, their biomechanical fit should also be considered.
function is to keep the respiratory tract open to minimize the harm of Such 3D printed structures are highly desirable matching the
injury caused by trauma or surgery (Sittel, 2009; Debry et al., 2017; biomechanical properties of the tissue (Gomes and Reis, 2004) and
Cooper, 2018). One of the challenges of such stenting is the possibility of closely mimicking in vivo behaviour, assisting the body to rebuild the
migration, for example, due to coughing or excessive physical loading. surrounding damaged tissue (Chung and Burdick, 2008; Wong, 2007).
* Corresponding author.
E-mail address: alexandra.zuhlke@aalto.fi (A. Zühlke).
https://doi.org/10.1016/j.jmbbm.2021.104649
Received 15 October 2020; Received in revised form 9 June 2021; Accepted 12 June 2021
Available online 16 June 2021
1751-6161/© 2021 Published by Elsevier Ltd.
A. Zühlke et al. Journal of the Mechanical Behavior of Biomedical Materials 122 (2021) 104649
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A. Zühlke et al. Journal of the Mechanical Behavior of Biomedical Materials 122 (2021) 104649
Fig. 2. An example of a frequency scan test principle, where the amplitude is constant but the frequency (F1 < F2 < F3) varies.
constant but the frequency is varied (Fig. 2). For all combinations, experimental observation of materials properties without assumption of
changes in length, stiffness, loss tangent, dynamic and static stress/ a material mechanistic model, method linearity, and without applica
strain ratios, viscosity, creep compliance, aggregate modulus, etc. were tion of Fourier transform or using complex numbers (Gasik and Bilotsky,
analysed. 2019). Whereas Fourier transform is a very useful and perfectly working
Tests were performed for compression mode and for 3-point bending tool for linear operations (in linear viscoelasticity), it fails for properties
at 10 mm span. All sample holders are automatically calibrated on as arbitrary functions of time or frequency (Neumark, 1962a). Gener
empty system stiffness, static, dynamic and rotation tuning, from which alized Fourier transforms such as the Fourier integral operators and
data are subtracted from the measured signal. In addition, in compres pseudo-differential operators could be used (Maslov, 1970), however,
sion mode a thermo-mechanical analysis (TMA) mode was applied to the drawback of this approach is in its strict adherence to certain types of
analyse thermal expansion of silicones up to 45 ◦ C. The deformation pseudo-differential equations and requirements of a deep knowledge of
values recorded by DMA (in μm) were converted into true logarithmic such functional techniques (Maslov, 1970; Neumark, 1962a). On the
strain. True strain is the only measure having solid thermodynamic contrary to these approaches, BEST does not employ differential equa
grounds among used strain forms (Norris, 2008; Lubarda and Chen, tions or series expansions, neither requires material homogeneity (the
2008; Xiao, 1995), although others might be used especially when the properties are evaluated for the whole specimen, i.e. closer to the con
deformations are small. True strain in this case is calculated for ditions which might be faced upon implantation). The BEST method
quasi-static loading (creep) conditions as does not stipulate that the material has to be compliant with some
⃒ ( )⃒ pre-selected physical model (elastic, viscoelastic, hyperelastic,
⃒ ΔL ⃒⃒
εstat = ⃒⃒In 1 + , (1) neo-Hookean, etc.). Selection of the material model in any combination
H0 ⃒
is a must for any conventional calculations in viscoelastic analysis or in
numerical computer simulations, but this may lead to wrong predictions
and for dynamic loading conditions as (Gasik and Bilotsky, 2019):
when the model assumptions do not hold. In this work BEST analysis was
( )
1 2adyn used to extract true (invariant) properties of elasticity, viscosity and
εdyn = In 1 + , (2)
2 H0 + ΔL − adyn their time and frequency dependences (Gasik and Bilotsky, 2019).
where H0 - initial dimension (height) of the specimen before the test, ΔL - 2.4. Biocompatibility testing
instant value of change of the static height, adyn - amplitude of the dy
namic displacement. Equation (2) takes into account the change in the Cytotoxicity by indirect contact was analysed with an extraction
specimen static dimensions during the test, incorporating loading his vehicle (the supplemented DMEM cell culture medium) in the contact
tory, and accounts for non-symmetry of the harmonic stimulus signal vs. with the material (moulded and 3D printed silicone samples, PET as
origin due to this. positive control, sodium azide NaN3 as negative control) for 24 h in the
incubator (5% CO2, 37 ◦ C). In parallel, the 3T3 cells are cultured in a cell
2.3. Mechanical data analysis culture dish until reaching 70–80% confluence in 24 h. On the second
day, the extraction vehicle was transferred to the cell mat and left in
With the conventional biomechanical readouts obtained directly contact for next 24 h before evaluating possible cell toxicity at the
from the DMA, advanced data analysis was carried out with BEST morphological level (microscopy) and at the level of viability (MTT
(Biomaterials Enhanced Simulation Testing). Briefly, BEST comprises test).
steps of 1) defining the proper physiologically relevant conditions for Cytotoxicity by direct contact was evaluated with the 3T3 cells first
your clinical application, 2) subjecting the specimen to coherent grown in a cell culture dish to reach 70–80% confluence within 24 h. On
biomechanical stimuli, inducing conditions closer to hostile environ the second day, the materials to be tested were placed in contact with
ment, 3) assessing changes in properties of the specimen in time, phase the cell mat and left for 24 h before evaluating possible cell toxicity at
and stimulus domains, 4) post-processing experimental readouts with the morphological level (microscopy) or at the level of viability (MTT
idempotent analysis (Gasik and Bilotsky, 2019; Maslov, 1970), incor test). For this test, the dimensions of the material should not exceed 10%
porating specimen history and 5) extracting true invariant values, suit of the surface of the cell layer. To keep the material in contact with the
able for material behaviour prediction in a form of model-free cell mat, a cell culture insert was used which was placed on the material.
constitutive equation for given biomaterial.
The differences between BEST and other methods are in direct
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A. Zühlke et al. Journal of the Mechanical Behavior of Biomedical Materials 122 (2021) 104649
Fig. 4. Surface characterization of moulded (SilM) and 3D printed (Sil3D) silicone samples using digital microscope.
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A. Zühlke et al. Journal of the Mechanical Behavior of Biomedical Materials 122 (2021) 104649
Fig. 5. Surface characterization and roughness determination (Ra) of moulded (SilM) and 3D printed (Sil3D) silicone samples using AFM.
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A. Zühlke et al. Journal of the Mechanical Behavior of Biomedical Materials 122 (2021) 104649
Fig. 8. Invariant stiffness (a) and viscosity (b) in compression for two silicone materials as function of applied stress. Vertical bars are standard errors.
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A. Zühlke et al. Journal of the Mechanical Behavior of Biomedical Materials 122 (2021) 104649
Fig. 9. Amplitude of the complex elastic modulus (a) and the loss tangent (b) as obtained by DMA, without data post-processing.
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A. Zühlke et al. Journal of the Mechanical Behavior of Biomedical Materials 122 (2021) 104649
Table 3 for analogous moulded part. Due to this deformation, the exerted stress
Expected static and dynamic (1 Hz) properties for silicone samples under might drop faster and therefore the primary stability of the implant
10 kPa stress. might be compromised even if biomechanical risk of stenosis would be
Parameter estimations SilM Sil3D minimized in this case. Dynamic stiffness at 1 Hz (i.e. closer to physi
Creep memory value α 0.020 0.009
ological pulse frequency) in these conditions for moulded silicone would
Creep stiffness E0, MPa 1.56 0.186 be about 3.8 times higher than for 3D printed one, meaning that the
Characteristic time τ0, sec 50.45 65.03 deflection of moulded part would be smaller and the exerted pressure to
Strain at creep at 10 kPa after 5 hours 0.007 0.054 soft tissues would be respectively higher if the deformation of the
Dynamic stiffness E0ω, MPa 8.03 3.44
implant is constrained by some means.
Dynamic invariant viscosity, η0ω, MPa⋅s 0.022 0.0125
Dynamic memory value αω 0.084 0.256 Pseudo-static (creep) and dynamic (frequency scan) analyses were
Dynamic stiffness, MPa 6.80 1.79 made with DMA, but the readouts were also additionally processed with
BEST (Vrana et al., 2020; Gasik and Bilotsky, 2019), which does not use
complex math, artificial models neither Fourier transforms. This leads to
data how much the static and dynamic deformation of the silicone stent a minimal set of parameters describing the mechanical process in static
would be feasible for a selected design, size, geometry and the status of and dynamics. As known, there are tangible practical and experimental
the patient (Table 3). costs for adding extra variables and parameters to the constitutive
It is seen that expected static (creep) deformation of 3D printed sil equation for describing the underlaying processes (Magin, 2010). When
icones after 5 h post-implantation would be about 8 times higher than the method uses less parameters, and when most of the parameters are
Fig. 10. Indirect cytotoxicity results for moulded (SilM) and 3D printed silicone (Sil3D), with PET as a positive control (~100% viability) and sodium azide imbibed
silicone as a negative control (~10% viability). Corresponding brightfield images of the cells after exposure.
Fig. 11. Direct contact cytotoxicity tests for moulded (SilM) and 3D printed silicone (Sil3D) with PET as positive and sodium azide imbibed silicone as negative
control. Corresponding brightfield microscopy images (10x).
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A. Zühlke et al. Journal of the Mechanical Behavior of Biomedical Materials 122 (2021) 104649
Fig. 12. Paravertebral subcutaneous implantation of moulded and 3D printed silicones. A) The implantation sites, the histological scoring and scoring criteria. B)
Histological sections after 2 weeks of implantation with haemotoxylin and eosin and Masson Trichrome staining.
invariants, it provides simpler, more concise and more consistent pre can be extended for the cases dominated by inertial or wave-propagation
diction for the biomaterial system without unnecessary complication of conditions (1 < α < 2), when linear approach becomes invalid (such
the calculations or ersatz-models. The appearance of Eqs. (3)–(6) for the as with negative loss tangent and strain energy density).
case of the testing modalities is close to known fractional viscoelasticity Whereas biomechanical properties and the surface of the materials
(Bagley and Torvik, 1983; Rodríguez et al., 2018; Coussot et al., 2009; show substantial differences, cytotoxicity of 3D-printed and moulded
Magin, 2010). However, here it was shown that the memory values α are samples does not alert about cell toxicity by direct contact since the cell
not constants and therefore traditional methods of fractional calculus viability is respectively 80% and 95% compared to the TCPS control. In
(Bagley and Torvik, 1983; Magin, 2010) or linear viscoelasticity (Neu addition, there is no morphological change in the cells which is another
mark, 1962b; Ewoldt et al., 2015) cannot be directly used. Biome criterion for confirming that all materials are not cytotoxic (Fig. 10). In
chanical data obtained with new method (Gasik and Bilotsky, 2019) do indirect contact, moulded silicone shows no cytotoxicity since full
not impose restrictions on the linearity of the system or material, and viability (100%) is maintained compared to the control, without cells
Fig. 13. In vivo systemic cytokine levels in mice at D1, D7 and D14 of implantation of moulded and 3D printed silicone samples compared to baseline read-outs.
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A. Zühlke et al. Journal of the Mechanical Behavior of Biomedical Materials 122 (2021) 104649
morphological change, with no clear effect by cell density populations Author statement
which one could potentially able to determine (Volfson et al., 2008).
There was a slightly higher viability results compared to 3D printed As the corresponding author I confirm on behalf of all the authors,
samples in this configuration but the viability with 3D printed samples that we have read and approved the revisions to this manuscript.
was still above 70% (the cytotoxicity threshold), Fig. 11.
After 2 weeks of implantation, the histology shows good healing
around both moulded and 3D printed silicone. The histological scoring Declaration of competing interest
resulted on a zero score for the 3D printed silicone (good healing, within
the scale of 0–3; where 3 corresponds to chronic inflammation), Fig. 12. The authors declare that they have no known competing financial
The moulded samples, on the other hand had a score of 0.4; but still interests or personal relationships that could have appeared to influence
within good healing index. The quantification of systemic cytokine the work reported in this paper.
levels showed a slight increase in the pro-inflammatory cytokines after
implantation at similar levels for both silicones. In most cases the dif Acknowledgments
ferences were insignificant; except on D1 moulded silicone samples
shown a higher TNF-α, MCP-1 and IL-27 levels - all pro-inflammatory This project has received funding from the European Union’s Hori
markers (Fig. 13). However, over the course of 2 weeks (D14), the zon 2020 research and innovation programme under grant agreement
levels were stable and cannot be considered to induce a systemic high No 760921 (“PANBioRA”; A.Z., M.G., N.E.V., J.B.) and from the “FUI-
level of inflammation where the read-outs <100 pg/ml range for any of FASSIL” project (J.B., C.B.M., N.E.V.)
the cytokines.
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