BED-Vol.

50, 2001 Bioengineering Conference

ASME 2001

MANUFACTURING COMPLEX COMPLIANT CARDIOVASCULAR SYSTEM MODELS

FOR IN VITRO HEMODYNAMIC EXPERIMENTATION USING CT AND MRI DATA AND
RAPID PROTOTYPING TECHNOLOGIES
R. Wicker (1), M. Cortez (1), F. Medina (1), G. Palafox (1), and C. Elkins (2)

(1) Mechanical and Industrial Engineering

Department
The University of Texas at El Paso
El Paso, TX 79968-0521

(2) Mechanical Engineering Department

Stanford University
Stanford, CA 94305-3030

INTRODUCTION
Cardiovascular disease is the number one killer in the United
States today. There has been much effort in the research community
to understand the pathogenesis of atherosclerosis and related arterial
disorders, and since atherosclerosis begins as highly localized,
sparsely distributed lesions, many believe atherosclerosis is related to
local hemodynamic phenomena in the affected artery. However, the
degree to which local flow characteristics can be related to plaque
formation has yet to be quantified. Our motivation for in vitro
experimentation is to examine local flow characteristics in an attempt
to identify potential fluid mechanic causative factors for localized
cardiovascular disease, such as atherosclerosis, aortic aneurysm, and
aortic dissection.
However, prior to performing in vitro
experimentation, complex cardiovascular system models are required.
Previously, researchers have conducted in vitro experimentation,
primarily examining flow characteristics in compliant or rigid models
that represent a small region of the affected artery. Although these
investigations have provided much useful information, the models lack
much of the complexity of the cardiovascular system, which
necessarily alters the flow boundary conditions. We have identified a
modeling process that allows for the development of large, complex
cardiovascular system models. The process utilizes a fused deposition
modeling (FDM) rapid prototyping (RP) system manufactured by
Stratasys, Inc. As part of the FDM process, a thermoplastic material is
extruded through a nozzle creating the model in layers. Since complex
three-dimensional (3D) objects are created using this machine, the
process requires two heads: one extruding the primary material and the
second extruding a support or release material. This process is
highlighted in Figure 1 where an abdominal aorta is being
manufactured. The left image shows the FDM machine manufacturing
the abdominal aorta out of an ABS plastic, also illustrating the amount
of support material required for this model. The right image illustrates
the final abdominal aorta model after the support material has been
removed. It is this support material that allows us to manufacture
complex cardiovascular system models.

Figure 1. Abdominal aorta ABS model manufactured using rapid

prototyping system (left showing the manufacturing process including
the ABS plastic primary build material and the WaterworksTM support
material, right showing the finished product).
The support material, called WaterWorksTM, is a 100% watersoluble material with a melting temperature of 230 C. Our process
for manufacturing complex cardiovascular system models involves
utilizing WaterWorksTM as a primary material for manufacturing
vascular molds. Silicone models are then created by either dipping the
mold in a silicone solution or injecting silicone into the mold. After
curing, the mold material is dissolved in water, leaving a compliant
vessel for hemodynamic studies. The following more fully describes
the manufacturing process required for complex, compliant vascular
system models. The manufacturing process is divided into three areas,
including the development of the geometric computer model, the
mold, and the vascular model.
MANUFACTURING PROCESS
Generating geometric computer models from MRI or CT imaging
data is the first step in manufacturing complex, compliant vascular

469

Copyright 2001 by ASME

system models. The methods for developing the geometric computer

models from the imaging data at present remain labor intensive, and
this process is not the focus of this discussion. In summary, we are
familiar with two commercially available software packages that can
be used to extract the arterial data from CT and MRI scans. Due to
inadequacies in the current segmentation methods used to extract the
major arteries in the imaging data, there are numerous potential
sources for error. However, with sufficient care and time, it is possible
to create an accurate computer model for use in the RP process. The
available commercial software is capable of producing both files in
either STL or SLI formats. Although the Stratasys machine uses SLI
files, we first create an STL file. We then scale the part to a desired
real dimension and generate an SLI file for rapid prototyping.
Using the FDM process, a part is manufactured layer-by-layer.
As described previously, the Stratasys FDM 3000 rapid prototyping
machine uses the WaterWorksTM material as a support material. In our
process, we utilize the WaterWorksTM material as the primary build
material. The support material utilized in our process is the same
thermoplastic support material used for making ABS parts without
using WaterWorksTM (an option available from Stratasys). After the
part is manufactured, the support material is separated from the model
by simply removing it or breaking it away.
Once the mold is manufactured, a series of steps is required to
achieve a silicone vessel free of imperfections. Ripples on the surface
are evident since the FDM machine manufactures the model in layers.
Sanding the part removes the ripples. In addition, a few imperfections
such as voids may result from the machining process. To fix these
imperfections, a soldering iron can be used to fuse material from a
spool of WaterWorksTM thread with the model. Once the model is
smooth, the development of the silicone vessel can begin.
Prior to dipping the model in a silicone-xylene mixture, the model
is pre-heated to ~80 oC to remove any moisture trapped within the
model. After each dip, the model is allowed to drain by holding it
vertically and spinning it manually. The draining of the silicone
serves to remove premature air bubbles and silicone build up around
the branch junctions. The model with the silicone coating is attached
to a rotating shaft for curing inside a forced air oven. The recipe for
making silicone vessels is as follows:
1.
2.
3.
4.
5.
6.
7.

to the resulting surface finish of the silicone vessel. In this particular

example, sanding and soldering the WaterWorksTM mold were used
for finishing and repairing, respectively. Pre-heating the mold also
was used to remove moisture trapped within the mold. The compliant
silicone vessel shown in the figure is clear and has minimal
imperfections, such as ripples, air bubbles, and silicone build up
around the sutures. The draining process implemented during each dip
and the rotational curing eliminate silicone build-up around the suture.
Furthermore, curing at low temperature (less than 50 oC) also prevents
the formation of air bubbles.

Figure 2. Model of pig aorta and bypass graft with the WaterWorksTM
mold on the left and compliant silicone vessel on the right.
The simple example shown in Figure 2 illustrates the quality of
vascular models produced using this technique.
The current
manufacturing methods are being adapted to create entire vascular
system models from CT and MRI scans. Segments of the system are
manufactured using the RP machine and put together utilizing the
soldering technique. As a result, we believe this technique will allow
entire cardiovascular system models to be manufactured for extensive
hemodynamic analyses.

Pre-heat the mold to ~80 oC for 20 minutes.

Dip into the silicone-xylene mixture, and implement the
draining process after each dip.
Expose the model to a temperature of ~30 oC for
approximately 1 hour.
Increase the temperature to 40 oC. Allow to cure for 1 hour.
Increase the temperature to 50 oC. Allow to cure for 1 hour.
Increase the temperature by 5 oC, every hour, until a
temperature of 80 oC is reached.
Lower the temperature to 50 oC and allow the model to
finish curing for an additional hour. Remove from oven.

The final step to obtain the silicone vessel is to remove the

WaterWorksTM material once the silicone cures. This is done by
placing it into an ultra-sonic bath to dissolve the WaterWorksTM
material.
RESULTS
As a demonstration of the manufacturing technique, Figure 2
contains a WaterWorksTM mold and silicone vessel for a stenosed pig
aorta with a bypass graft. The mold shown in the figure is prior to
finishing, and as mentioned previously, finishing is critically important

470

Copyright 2001 by ASME