Innovation through design: 3D printing and desktop injection molding system for biomedical applications

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Silicone injection molding is an essential need in the NSERC Discovery Grant Programs of Drs. McLean and Labrosse, yet up until now, such capacity has been out of reach. To date, machines have been large and very costly, with limited versatility as they are tuned to specific applications. Indeed injection molding systems have had limited value as an infrastructure investment for academic researchers. Just this year however, the first desktop injection molding system compatible with silicone was launched by Structur3D, a Canadian company. A second desktop system is also soon to be available by APSX-PIM. Such emerging technology is essential to support the development of devices to meet urgent research needs of Drs. McLean, Labrosse and others.***Dr. McLean's NSERC DG program is actively focusing on device design for commercialization. She currently requires capacity for rapid prototyping of device parts in plastic (ABS/PLA) and in medical grade silicone needs that she cannot meet with tools available in her lab or more generally on campus. Through his NSERC DG program, Dr. Labrosse is developing, testing and validating new tools to help cardiac surgeons with the planning of repair procedures on the aortic valves. He urgently needs to generate aortic valve models that will be used both as surrogates for surgical training, as well as to verify and validate advanced computer simulation tools for the planning of aortic valve repair. The Structur3D system is ideal for these applications as models can easily be refined using several design iterations and material properties. This flexibility will also facilitate sharing with several identified users who require access to 3D print capability using dual extrusion or to prototype devices using injection molding. This is an ideal infrastructure investment. ***The proposed Structur3D system includes an Ultimaker S5 dual extrusion 3D printer, ultrasonic bath and vacuum hood coupled with the Discov3ry automated, dual extrusion injection molding system. This system is truly state-of-the art. The product, just launched in October 2019, will allow researchers to generate their own molds and mix their own materials to customize properties to their applications. In the case of Dr. McLean's work, the system allows her to use medical grade silicone (i.e., Nusil), an essential material for her devices. ***Both Drs. McLean and Labrosse have excellent mentoring records and strive to recruit and support their HQP through processes that reflect the principles of equity, diversity and inclusion. The requested on-site training will ensure that trainees quickly become competent at rapid prototyping. This will generate a local pool of highly qualified personnel who can train and mentor new users. HQP will learn advanced approaches to iterative device design, prototyping and testing in a real-world environment skills that are highly transferable to the rapidly evolving area of biomedical device design and optimization.*****