Fabrication of flexible intracranial aneurysm models using stereolithography 3D printing

The use of 3D printing technology for medical applications is becoming increasingly popular. Recent stereolithography (SLA)-based printing methods allow the generation of complex structures with a high surface quality. This is particularly useful for applications in the neurovascular field, where sophisticated structures are involved. In this study patient-specific intracranial aneurysm models are extracted based on medical image data und printed as thin-walled vascular phantom models. For this purpose, two commercially available 3D printers are used to print flexible vascular models with three different silicone-like elastic resins (Ultracur3D FL 300, Prusament Flex80 and Formlabs Elastic 50A) of various Shore hardness. Three aneurysm models of different size and complexity are chosen. To evaluate the geometric accuracy of the flexible models, angiographic measurements are performed for an exemplary case and morphological parameters are extracted from the generated 3D models. The printed results demonstrate a successful generation of hollow aneurysm phantoms. There are dependencies regarding the print quality from the model to platform positioning for two materials. The quantitative geometric accuracy analysis shows notable differences between the materials. The extracted morphological parameter values for all materials show a mean decrease compared to the original reference model of aneurysm volume (4.5 %) and maximum diameter (1.0 %) as well as an increase of ostium area (6.0 %) and maximum height (4.9 %). However, Formlabs Elastic 50A in particular exhibits just slight reductions with respect to the reference model, with a mean decrease for all parameters of 5.7 % as well as no dependence on printing position and resulting artifacts. The study investigates the feasibility of using SLA-based 3D printing to generate realistic flexible aneurysm phantoms. In this context, the Formlabs Elastic 50A could be identified as potentially applicable for phantom creation in terms of reproducible quality and geometric validity.