SBIR Phase I:Additive Manufacturing for Soft Tissue Repair by Three-Dimensional Microfiber Fabrication (3DMF)

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase I project isto improve the outcomes for implant procedures for soft tissue healing. More than 2 million musculoskeletal repair surgeries are performed in the U.S. each year, representing a $5 B market. Instead of conventional 3D printing that completely melts or fuses synthetic biopolymers into solid and rigid objects, this project will develop a novel 3D microfiber printing process project to rapidly and economically produce clinical-grade printed implants with better performance.This technology will offer a significant reduction in the cost of goods and a faster product development cycle. The novel implants will be available in markets wherein existing products are prohibitively expensive, including ambulatory surgical centers, wherein most of these surgical procedures are performed.This Small Business Innovation Research (SBIR) Phase I project will progress the design and engineering for a novel 3D microfiber printer that can assemble clinically relevant synthetic biopolymer filaments into fibrous, flexible, high void/porosity implants to promote soft tissue healing. This approach offers improvements in quality, cost, speed, and manufacturability. This project will explore the material strength, cytocompatibility, and biocompatibility using industry-standard testing. Expected technical results include quantitative measures for a controlled fibrous 3D printing method compatible with diverse synthetic biopolymers and across clinical indications. This project will optimize the hardware engineering, polymer, and print configuration.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.