Apparatus and method for producing a biocompatible three-dimensional object

Abstract

An apparatus for making a biocompatible three-dimensional object including at least one delivery unit arranged to deliver at least one biocompatible fluid substance towards a support body having a matrix surface to obtain a coating layer of a predetermined thickness configured for coating the matrix surface. Furthermore, a handling unit is provided arranged to provide a relative movement according to at least 3 degrees of freedom between the support body and each delivery unit. The support body is arranged to be coated by the delivered biocompatible fluid substance, in order to obtain a three-dimensional object having an object surface copying the matrix surface of the support body.

Claims

1. An apparatus for making a biocompatible three-dimensional object, the apparatus comprising: a support body having a matrix surface with at least two radii of curvature; a handling unit supporting the support body; a delivery system arranged to deliver a biocompatible fluid substance having a plurality of particles towards the support body to obtain a coating layer of a predetermined thickness coating the matrix surface; a control unit arranged to monitor the thickness of the coating layer; a single suction and blowing device arranged to generate a suction or blowing current, the suction and blowing current configured to remove from the support body any surplus particles of the biocompatible fluid substance supplied by the delivery system; and a counter-mold that is adapted, once the delivery of the biocompatible fluid substance is completed, to press the coating layer deposited on the support body, wherein the handling unit is arranged to generate a relative movement with at least three degrees of freedom between the support body and the delivery system, in such a way that the support body can be coated with the delivered biocompatible fluid substance to obtain a three-dimensional object having an object surface corresponding to the matrix surface of the support body.

2. The apparatus of claim 1, wherein the handling unit includes an anthropomorphic robot having a chain of pivot joints, the chain of pivot joints having an end connected to a fixed base and the other end connected to a support base to which the support body or the delivery system can be removably mounted, the chain of pivot joints arranged to move the support body or the delivery system, according to at least six degrees of freedom.

3. The apparatus of claim 1, wherein the handling unit includes a plurality of linear actuators, each actuator of the plurality having an end engaged with a fixed base and another end engaged with a support base to which the support body or the delivery system is removably mounted.

4. The apparatus of claim 1, wherein the suction and blowing device is fixed.

5. The apparatus of claim 1, wherein the suction and blowing device is movable and associated with auxiliary moving means arranged to move the suction and blowing device, the auxiliary moving means being configured to allow the suction and blowing device to follow spatially the position of the support body during its handling by the handling unit.

6. The apparatus of claim 1, wherein the suction and blowing device includes a suction hood integral to the support base and configured to surround laterally the support body, in order to maximize the suction of the surplus particles of the biocompatible fluid substance, and a suction tube arranged to connect pneumatically the suction hood with a suction system.

7. The apparatus of claim 1, wherein the delivery system includes a first delivery unit arranged to deliver a first jet of the biocompatible fluid substance towards the support body, the biocompatible fluid substance being a biomaterial of synthetic origin, and a second delivery unit arranged to deliver a second jet of a second biocompatible fluid substance towards the support body, the second biocompatible fluid substance being a non-solvent, the second delivery unit arranged to direct the second jet towards the support body in such a way that the second jet overlaps the first jet, inducing a quick deposit of the synthetic biomaterial supplied onto the support body from the first delivery unit obtaining a filamentous three-dimensional structure.

8. The apparatus of claim 7, wherein the second biocompatible fluid substance is water.

9. The apparatus of claim 7, wherein the delivery system includes a third delivery unit arranged to deliver a third biocompatible fluid substance.

10. The apparatus of claim 9, wherein the third biocompatible fluid substance is a biopolymeric material of synthetic origin.

11. The apparatus of claim 1, wherein the thickness of the coating layer is capable of being adjusted.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present disclosure will be now shown with the following description of some exemplary embodiments thereof, exemplifying but not limitative, with reference to the attached drawings in which:

(2) FIG. 1 shows an exemplary embodiment of an apparatus including an anthropomorphic robot arranged to handle the support body;

(3) FIG. 2 shows an exemplary embodiment of an apparatus, which differs from that of FIG. 1 for the presence of a toroidal hood arranged to surround the support body;

(4) FIG. 3 shows an exemplary embodiment of the apparatus, which differs from that of FIG. 2 since the handling unit the support body does not include an anthropomorphic robot, but a plurality of linear actuators;

(5) FIG. 4 shows a counter-mold that allows a hot molding of the coating layer;

(6) FIG. 5 shows a three-dimensional object resulting from the production process;

(7) FIG. 6A shows a cardiac chamber with a heart patch applied to it; and

(8) FIG. 6B shows a support from which the heart patch of FIG. 6A is generated.

DETAILED DESCRIPTION

(9) With reference to FIG. 1, an exemplary embodiment of an apparatus 100 for making a biocompatible three-dimensional object 30 provides an anthropomorphic robot 132 having a kinematical chain of pivot joints 133. Such chain of joints 133 is constrained at an end to a fixed base 134, and at another end to a support base 131 on which support body 20 engages in a removable way. The chain of pivot joints 133 of FIG. 1 allows handling the support body according to six degrees of freedom, allowing an optimum precision when generating the sought three-dimensional object 30.

(10) In FIG. 1, three delivery units 110,111,112 are shown that are arranged to deliver three different biocompatible fluid substances. In particular, first delivery unit 110 is adapted to deliver a jet of a biomaterial of synthetic origin towards the support body 20. The second delivery unit 111 is, instead, arranged to deliver a jet of non-solvent, for example water, overlapping to the jet generated by first delivery unit 110, in order to induce a quick deposit of the biopolymeric material supplied onto support body 20 by first delivery unit 110, allowing to obtain a filamentous three-dimensional structure. The third delivery unit, finally, is adapted to deliver a third biocompatible fluid substance diluted in solution, in particular another biomaterial of synthetic or biological origin.

(11) Each delivery unit 110,111,112 also has a hydraulic circuit (not shown in the figure, for example, a cylinder-piston mechanism) consisting of ducts, with possible valves and pumps, which connect the or each delivery unit to reservoirs containing the biocompatible fluid substances.

(12) In this exemplary embodiment, a suction and/or blowing unit 120 is further provided, adapted to generate a suction and/or blowing current. This way, the suction and/or blowing unit 120 makes it possible to level the thickness of the coating layer 35 and to remove from support body 20 any surplus particles of the biocompatible fluid substances supplied by the or each delivery unit 110, 111, 112. The device 120 is also spatially moved by auxiliary moving means 140, in such a way that this device 120 can follow spatially the position of support body 20 during its handling steps by handling unit 130.

(13) In FIG. 2 a second exemplary embodiment is shown, which differs from an exemplary embodiment of FIG. 1 as from the type of the device 120. In this exemplary embodiment, device 120 includes a toroidal suction hood 121, which is integral to support base 131 and is configured to surround laterally support body 20. Toroidal hood 121 is then joined to a suction tube 122 arranged in turn to connect pneumatically the suction hood 121 with a suction system 123 that has a compressor to generate a suction flow and with a storage reservoir containing any surplus particles of the dispensed fluid substance.

(14) Alternatively, in an exemplary embodiment not shown in the figures, device 120 is a blowing device including a compressor adapted to generate a blowing current for removing any surplus particles of the delivered fluid substance. This way, it is not necessary that the apparatus includes auxiliary handling unit 140, like the exemplary embodiment of FIG. 1, since the toroidal hood 121 surrounds laterally the support body 20, whichever is the position reached by handling unit 130.

(15) In FIG. 3 an exemplary embodiment is shown where handling unit 130, instead of including the anthropomorphic robot 132 of the previous figures, includes a plurality of linear actuators 133, each of which engages, at one end, to fixed base 134, and at another end, to support base 131. Support body 20 engages in a removable way with support base 131, like the previous exemplary embodiments. The handling unit can reach the same degrees of freedom of an anthropomorphic robot, even if with narrower handling range. The advantage offered by this solution is shown by a high reduction of the encumbrance.

(16) In FIG. 4 the step is shown of pressing, in particular to hot pressing, of the coating layer 35 deposited by the or each delivery unit 110,111,112, using a counter-mold 150. The coating layer 35 is then removed from support body 20 and becomes substantially the final biocompatible three-dimensional object 30, visible in FIG. 5.

(17) Owing to the hot pressing an optimum finishing of the shape of the three-dimensional object 30 can be achieved, in such a way that such shape is closest to the designed patch shape, for example provided by CAD or the like. Such pressing operation also gives to the three-dimensional object 30 mechanical improved features, reaching any design standards.

(18) The apparatus 100, as described above, and shown in FIGS. 1 to 5, provides biocompatible three-dimensional objects 30 of whichever shape. In particular, biocompatible three-dimensional objects 30 can be manufactured both of simple and regular shape, such as a tetrahedron or a cone, and of irregular shape and/or with surfaces which cannot worked out in a simple way, such as a concave or convex patch or an ellipsoidal patch. Furthermore, biocompatible three-dimensional objects 30 can be provided having surfaces with different radius of curvature and/or with different angles.

(19) In FIG. 6A a cardiac chamber of a human heart is shown to which a biocompatible three-dimensional object 30 is mounted, in particular a heart patch, consisting of an inner portion 30a and an external portion 30b.

(20) In FIG. 6B part of the apparatus 100 including the support 20 is shown, from which the inner portion 30a of the heart patch of FIG. 6A is generated.

(21) The foregoing description of specific exemplary embodiments will so fully reveal the invention according to the conceptual point of view, so that others, by applying current knowledge, will be able to modify and/or adapt in various applications the specific exemplary embodiments without further research and without parting from the invention, and, accordingly, it is meant that such adaptations and modifications will have to be considered as equivalent to the specific embodiments. The means and the materials to realize the different functions described herein could have a different nature without, for this reason, departing from the field of the invention, it is to be understood that the phraseology or terminology that is employed herein is for the purpose of description and not of limitation.

(22) The above described application relates to the MBP project “Fibrin-based nanostructured materials and platelet factors for stimulating angiogenesis” (“Materiali nanostrutturati a base di fibrina e fattori piastrinici in grado di promuovere 1′ angiogenesi”) admitted to R.T. financing, R&D Single Announcement, year 2008, 1.5-1.6 line B-Executive Decree 6744 of Dec. 31, 2008.