Development of a polymeric aortic valve implant for manufacture in Ultrasonic Injection Molding

Abstract

This thesis, part of the Master of Science in Manufacturing Systems program, presents an innovative proposal to address the challenges inherent in biological heart valve implants, specifically those crafted from animal pericardium. Focusing on the development of a polymeric aortic valve implant prototype, the study employs Ultrasonic Injection Molding (UIM) technology known for its capabilities in minimizing material waste and enhancing manufacturing efficiency. The research delves into the nuances of UIM manufacturing, investigating the processing window’s best parameters and conducting a following optimization to improve the mechanical properties of the resulting implant. The mechanical characterization of Thermoplastic Polyurethane (TPU), the chosen material, adds depth to the understanding of its behavior, ensuring suitability for medical applications. Complementing the manufacturing advancements, the study includes the design and prototyping of the aortic valve implant. Subsequent simulation through Computer-Aided Engineering (CAE) is employed to analyze the fluid dynamics facilitated by the valve design. This approach aims to provide comprehensive insights into the performance and efficacy of the polymeric aortic valve implant. Motivated by the limitations of traditional biological heart valve implants, including the necessity for reimplantation and the intricate, artisanal manufacturing processes leading to the wastage of animal pericardium, this research introduces a forward-thinking solution. Leveraging UIM technology, optimizing processing parameters, and integrating CAE simulation, the study seeks to innovate aortic valve implant manufacturing, offering a more efficient and resilient alternative to current practices.