Strategies for Creating Cardiovascular Models with Digital Light Projection Stereolithography

Stereolithography (SLA) represents an additive manufacturing method that uses light to selectively cure a photoresin for the purpose of creating a 3 dimensional structure. With successively cured layers, large geometry (4" x 6" x 15") can be achieved with incredibly high resolution (~100 micrometer). Using a digital light projection (DLP) chip, whole layers of the model can be cured in a single step as opposed to laser based methods that require the laser to line scan the model. This approach rapidly accelerates the printing process, while still maintaining a high level of accuracy in the part. The goal of this printer is to produce models of the cardiovascular system for benchtop flow studies. With many of the intended models being complex in nature, fused filament printing would not produce the needed resolution or finish required. The challenge with many models is how segment the model for printing, curing settings, and how to position the geometry on the print bed. Different photoresin chemistry's were used achieve specific model objectives, reusable molds, dissolvable molds, and device prototypes. The underlying chemistry, printing strategies, and discussion of the tested solutions to problems with this technology will be covered. With the growing presence of DLP SLA, many of the challenges with this method are limiting the success of these designs in the marketplace. This presentation will cover the advances made with the current design and the benefits this technology has for this application.