Additive Manufacturing of Bioresorbable Tracheal Stents from PDO/PCL Blends: Effects of Composition and Processing on Structure and Properties

Fused deposition modeling (FDM) is an additive manufacturing (AM) technology that enables the fabrication of complex and patient-specific devices made of biodegradable polymers. The successful implementation of the process requires exhaustive control of the workflow, focusing on material selection, device design, and manufacturing parameters. The aim of this study is to evaluate and compare the printability, processability, and mechanical performance of a polymer blend for the fabrication of customized airway stents using FDM printing, with a focus on its potential industrial scalability. Two FDM manufacturing approaches were evaluated using standard geometries to manufacture a blend of biodegradable polymers, using either filaments or pellets as feedstock. Moreover, the suitability of a blend made of polycaprolactone (PCL) and polydioxanone (PDO) for manufacturing tracheal stents was studied in comparison to their pure forms. Regarding the manufacturing technology, the feeding method itself was not the primary factor affecting the mechanical properties of the printed components, which was directly related to the geometry of the device and the cooling time polymers required. Furthermore, although the PCL/PDO blend showed a slightly higher mean elastic modulus than pure PCL, the resulting material did not exhibit sufficient radial resistance for airway stent applications. The design and development of 3D-printed medical devices require an evaluation of the entire manufacturing workflow. Device geometry and material selection are strongly influenced by the manufacturing technology selected and have a direct impact on the mechanical performance of the final product.