Introducing 3D-potting: a novel production process for artificial membrane lungs with superior blood flow design

Bio-Design and Manufacturing, vol. 5, pp. 141–152

Abstract

Abstract Currently, artificial-membrane lungs consist of thousands of hollow fiber membranes where blood flows around the fibers and gas flows inside the fibers, achieving diffusive gas exchange. At both ends of the fibers, the interspaces between the hollow fiber membranes and the plastic housing are filled with glue to separate the gas from the blood phase. During a uniaxial centrifugation process, the glue forms the “potting.” The shape of the cured potting is then determined by the centrifugation process, limiting design possibilities and leading to unfavorable stagnation zones associated with blood clotting. In this study, a new multiaxial centrifugation process was developed, expanding the possible shapes of the potting and allowing for completely new module designs with potentially superior blood flow guidance within the potting margins. Two-phase simulations of the process in conceptual artificial lungs were performed to explore the possibilities of a biaxial centrifugation process and determine suitable parameter sets. A corresponding biaxial centrifugation setup was built to prove feasibility and experimentally validate four conceptual designs, resulting in good agreement with the simulations. In summary, this study shows the feasibility of a multiaxial centrifugation process allowing greater variety in potting shapes, eliminating inefficient stagnation zones and more favorable blood flow conditions in artificial lungs. Graphic abstract

Authors 10

1. Felix Hesselmann corresponding Aachen Department of Cardiovascular Engineering Institute of Applied Medical Engineering

   RWTH Aachen University

   Affiliation as printed

   Department of Cardiovascular Engineering, Institute of Applied Medical Engineering, Helmholtz Institute, RWTH Aachen University, Pauwelsstrasse 20, 52074, Aachen, Germany

2. Jannis Focke Aachen Department of Cardiovascular Engineering Institute of Applied Medical Engineering

   RWTH Aachen University

   Affiliation as printed

   Department of Cardiovascular Engineering, Institute of Applied Medical Engineering, Helmholtz Institute, RWTH Aachen University, Pauwelsstrasse 20, 52074, Aachen, Germany

3. Peter Schlanstein Aachen Department of Cardiovascular Engineering Institute of Applied Medical Engineering

   RWTH Aachen University

   Affiliation as printed

   Department of Cardiovascular Engineering, Institute of Applied Medical Engineering, Helmholtz Institute, RWTH Aachen University, Pauwelsstrasse 20, 52074, Aachen, Germany

4. Niklas B. Steuer Aachen Department of Cardiovascular Engineering Institute of Applied Medical Engineering

   RWTH Aachen University

   Affiliation as printed

   Department of Cardiovascular Engineering, Institute of Applied Medical Engineering, Helmholtz Institute, RWTH Aachen University, Pauwelsstrasse 20, 52074, Aachen, Germany

5. Andreas Kaesler Aachen Department of Cardiovascular Engineering Institute of Applied Medical Engineering

   RWTH Aachen University

   Affiliation as printed

   Department of Cardiovascular Engineering, Institute of Applied Medical Engineering, Helmholtz Institute, RWTH Aachen University, Pauwelsstrasse 20, 52074, Aachen, Germany

6. Sebastian Daniel Reinartz Aachen Department of Diagnostic and Interventional Radiology

   Universitätsklinikum Aachen

   Affiliation as printed

   Department of Diagnostic and Interventional Radiology, Uniklinik RWTH Aachen, Pauwelsstrasse 30, 52074, Aachen, Germany

7. Thomas Schmitz‐Rode Aachen Department of Cardiovascular Engineering Institute of Applied Medical Engineering

   RWTH Aachen University

   Affiliation as printed

   Department of Cardiovascular Engineering, Institute of Applied Medical Engineering, Helmholtz Institute, RWTH Aachen University, Pauwelsstrasse 20, 52074, Aachen, Germany

8. Ulrich Steinseifer Aachen Department of Cardiovascular Engineering Institute of Applied Medical Engineering

   RWTH Aachen University

   Affiliation as printed

   Department of Cardiovascular Engineering, Institute of Applied Medical Engineering, Helmholtz Institute, RWTH Aachen University, Pauwelsstrasse 20, 52074, Aachen, Germany

9. Sebastian Victor Jansen Aachen Department of Cardiovascular Engineering Institute of Applied Medical Engineering

   RWTH Aachen University

   Affiliation as printed

   Department of Cardiovascular Engineering, Institute of Applied Medical Engineering, Helmholtz Institute, RWTH Aachen University, Pauwelsstrasse 20, 52074, Aachen, Germany

10. Jutta Arens Aachen Department of Cardiovascular Engineering Institute of Applied Medical Engineering

    RWTH Aachen University · University of Twente

    Affiliation as printed

    Department of Biomechanical Engineering, Faculty of Engineering, Technology University of Twente, Drienerlolaan 5, 7522 NB, Enschede, The Netherlands

    Department of Cardiovascular Engineering, Institute of Applied Medical Engineering, Helmholtz Institute, RWTH Aachen University, Pauwelsstrasse 20, 52074, Aachen, Germany