Digital light processing of round window niche implant prototypes for implantation studies

Abstract

A new approach that offers the potential for local drug delivery to the inner ear is a 3D printed, patient individualized, drug-loaded implant that precisely fits into the round window niche (RWN). Anatomically correct digital light processing (DLP) 3D printed implant prototypes are beneficial for preoperative planning and rehearsal of implantation techniques due to tactile feedback. The aim is to define desired mechanical material properties for future RWN implants. For this purpose, RWN implant prototypes (RWN-IPs) were DLP 3D printed using commercially available E-Shell 500 and E-Shell 600 materials (Envisiontec GmbH, Gladbeck, Germany) and a self-established PEGDA700 composition. These photopolymers are suitable for 3D printing RWN-IPs that feature different mechanical characteristics. The (1) mechanical properties (tensile test) were investigated, (2) the implantation feasibility and (3) fitting accuracy in human cadaver RWN were evaluated. As a result, E-Shell 500 has relatively high stretchability (εm ~ 60%) while E-Shell 600 and PEGDA700 are brittle and PEGDA700 has low strength. The E-Shell 500 material performs by far the best at handling and insertion. E-Shell 600 has adequate strength but is hard to handle because of rigid material behavior. PEGDA700 enables high 3D printing accuracy but lacks adequate mechanical behavior for adequate insertion of implant prototypes in RWN.