A hybrid biofabrication platform for patient-specific aortic phantoms: from surgical rehearsal to device testing.

Authors

Qingzhuo Chi, Guofeng Wang, Wenjun Wang, Xijing Zhuang, Yuanzhe Jin, Bo Liu, Ying He

Published in

Computer assisted surgery (Abingdon, England). Volume 31. Issue 1. Pages 2694865. Epub Jul 09, 2026.

Abstract

Fabricating high-fidelity, patient-specific aortic phantoms that possess both complex pathological features and physiological compliance remains a significant challenge for single-method manufacturing techniques. This study presents a complete virtual-to-physical prototyping workflow, enabled by a novel Hybrid Additive Manufacturing Platform (HAMP), for translating clinical imaging data into high-fidelity, patient-specific aortic phantoms. Building upon a validated brush-spin-coating technique capable of precise wall thickness control (±0.1 mm), the HAMP synergistically integrates 3D printing and casting. This integration overcomes the limitations of single-method techniques, uniquely enabling the creation of phantoms with (i) controllable interlayer delamination for mimicking dissection, (ii) enclosed multi-chamber structures for endoleak simulation, (iii) seamless integration of dissimilar materials, and (iv) the replication of complex intra-wall pathologies such as intramural hematoma. The platform's capability was rigorously demonstrated through the successful fabrication and application of four distinct classes of aortic phantoms. These high-fidelity models were directly employed in: fundamental biomechanical studies to visualize dissection propagation; advanced surgical training for complex procedures like ex vivo fenestration; emergency preoperative planning, where a patient-specific model was delivered in under 30 h; and industrial medical device testing using parametric, ISO-compliant models. In each scenario, the phantoms provided functional, anatomically accurate representations suitable for the intended evaluation-whether physical testing, surgical rehearsal, or hydrodynamic assessment. In summary, the HAMP demonstrates a rapid virtual-to-physical prototyping workflow. By enabling the on-demand creation of complex, multi-material, patient-specific phantoms, it provides a versatile tool that bridges digital data and physical reality, addressing needs across research, clinical training, and device development.

PMID:
42423970
Bibliographic data and abstract were imported from PubMed on 09 Jul 2026.

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