3D printing for Growth Adaptive Medical Devices: an alternative approach for craniosynostosis

An adaptive medical device is a piece of equipment designed to adjust or respond to changes in a patient’s condition or environment. The use of 3D printing technology for the development of adaptive medical devices has opened up new possibilities for customization, efficiency, and accessibility in healthcare. Sagittal craniosynostosis is a birth defect that arises due to a premature fusion of the sagittal suture in infants. This disease causes a misshapen skull and a rise of intracranial pressure that can lead to cognitive impairments. At six months of age, the preferred technique for craniosynostosis is an open vault remodeling surgery, an extremely invasive procedure with severe blood loss for the patient and significant postoperative pain. In this context, growth adaptive cranial plates, that can be tuned depending on the patient to achieve the desired skull shape through the deformation of the structure, can be a valid alternative. Cellular and lattice structures offer tailorable mechanical properties in relation to the designed geometry. Specifically, the geometry of cellular materials can be modified in relation to the final mechanical requirements. In this study, the predictability of the deformation of a PLA structure composed by honeycomb unit cells was studied performing compression simulations. The geometry was then modified, simulations and compression tests were then repeated in order to find an equation that could describe the relation between the internal angle of the honeycomb and the relative Poisson ratio. This relation can be further exploited for the production of customized adaptive devices for the treatment of sagittal craniosynostosis.