Rapid and Accurate Manufacture of 3D Vascular Replicas with Smooth Inner Surfaces Using Wax-Coated Molds

Abstract

3D vascular replicas are an economical and ethical training platform that can simulate endovascular intervention. During the manufacture of elaborate 3D vascular replicas through sacrificial molding, the surface of the 3D-printed pristine molds should be smoothed because the 3D-printed layered filament is transferred to the inner surface of the replicas. However, conventional smoothing methods using organic solvents take >3?d, thereby limiting the emergency use of 3D vascular replicas. This study demonstrates the rapid and accurate manufacture of 3D vascular replicas with a smooth inner surface using wax-coated molds. The wax coating can smooth the surface of the 3D-printed pristine molds in ?30 s, reducing processing time by >3?d. In addition, the thin and even wax coating, except for structures with a radius of curvature less than 2.5?mm or diameter less than 3?mm, facilitates the manufacture of elaborate 3D vascular replicas. The resulting replicas represent an internal vascular structure with high transmittance (?90%) and mechanical properties similar to those of blood vessels, including Young's modulus and friction coefficient. Thus, the prepared 3D vascular replicas using wax-coated molds can be applied as endovascular simulators in emergency situations. ? 2021 Wiley-VCH GmbH.