Patient-specific cardiovascular superelastic NiTi stents produced by laser powder bed fusion

To date, there is a general lack of customizability within the selection of endovascular devices for catheter-based vascular interventions. Laser powder bed fusion (LPBF) has been flexibly exploited to produce customized implants using conventional biomedical alloys for orthopedic and dental applications. Applying LPBF for cardiovascular applications, patient-specific stents can be produced with small struts (approximately 100-300 µm), variable geometries, and clinically used metals capable of superelastic behaviour at body temperature (eg. equiatomic nickel-titanium alloys, NiTi). Additionally, the growing availability and use of patient-specific 3D models provides a unique opportunity to outline the necessary manufacturing process that would be required for customizable NiTi devices based on patient geometry. In order to fulfil the potential of the patient-specific superelastic stents, process and design know-how should be expanded to the novel material and fine details at the limits of conventional LPBF machines. In this work, a framework for developing a patient-specific superelastic NiTi stent produced by LPBF is demonstrated. At a proof-of-concept stage, the design procedures are shown in a geometry similar to the artery. The stents with 100 µm nominal strut diameter are later produced with a Ni50.8Ti49.2 powder and heat treated. The results confirm the possibility of producing stents with a design suitable for highly complex patient-specific anatomies and having superelastic behavior at body temperature.