Advanced internally structured implant with tunable PDMS lattice and capsule

Overview

This implant concept uses a fully cured, three-dimensional PDMS lattice surrounded by a capsule. The lattice architecture can be adjusted to produce a wide range of mechanical stiffnesses, enabling device manufacturers to tailor the implant to patient and surgeon preference based on geometry rather than internal fill material. This approach reduces reliance on low-molecular-weight fillers, which can be mobile and may present concerns related to oligomers and residuals. It also broadens the range of design choices available for implant customization.

Technical specifications

Key design elements:

• Fully cured PDMS lattice provides the structural stiffness and texture of the implant.
• A surrounding capsule contains the lattice and creates the final implant form factor.
• Stiffness is controlled by the lattice structure, not by the fill material, enabling a wide range of mechanical properties.
• In-lab mechanical testing of the prototype material has demonstrated a stiffness range from approximately 0.4 kPa to 200 kPa.
• A novel additive manufacturing technique enables rapid, large-scale fabrication of the lattice.
• The approach can use commercial off-the-shelf PDMS systems with established performance in a variety of applications.
• Post-treatment can remove low-molecular-weight materials from the well-crosslinked lattice.

Technology readiness level

The prototype material has been validated in laboratory conditions, including mechanical testing across the target stiffness range. The proposed research plan is designed to expand and demonstrate the solution in a form factor relevant to the clinical challenge, with an estimated timeline of one to two years depending on sponsor goals. Support would fund researcher and principal investigator time, materials, and any required third-party validation of material performance claims.