Minimise thermo-mechanical batch variations when processing medical grade lactide based copolymers in additive manufacturing

Additive manufacturing is suitable for producing complex geometries; however, variation in thermomechanical properties is observed during one batch cycle when degradable aliphatic polyesters are used in melt extrusion-based methods. This is one important reason for why additive manufacturing has not yet been fully utilised to produce degradable medical implants. Herein, the internal variation has been minimised during one batch cycle by assessing the effect of different processing parameters when using commercially available medical grade copolymers. To minimise the molar mass, thermal and mechanical variation within one batch cycle, the rheological fingerprint of the commercially available medical grade poly(L-lactide-co-epsilon-caprolactone) and poly(Llactide-co-trimethylene carbonate) has been correlated to the process parameters of the ARBURG Plastic Freeforming. An increase in the temperature up to 220 degrees C and the associated increase in pressure are beneficial for the viscoelastic and thermally stable poly(L-lactide-co-epsilon-caprolactone). In contrast, a temperature below 220 degrees C should be used for the poly(L-lactide-co-trimethylene carbonate) to reduce the variation in strain at break during one batch cycle. The residence time is decreased through the increase of the discharge parameter. An increase in temperature is however required to reduce the viscosity of the polymer and allow the pressure to stay within the machine limitations at higher discharge parameters. The results are highly relevant to the development of additive manufacturing for the production of degradable medical devices with identical properties. In fact, Food and Drug Administration guidelines for additive manufacturing of medical implants specify the need to control changes in for example material properties during the process. (C) 2020 Elsevier Ltd. All rights reserved.