Layered manufacturing utilizing foam as a support and multifunctional material for the creation of parts and for tissue engineering

Abstract

One aspect of the invention provides a solid freeform fabrication method of creating a three-dimensional article built at least in part from scaffolding layers. The method includes: providing a scaffolding material; providing a supporting material in a shape of a foamy layer; and contacting the scaffolding material with the foamy layer to form at least one scaffolding layer and thereby creating the three dimensional article. Another aspect of the invention provides a three-dimensional article manufactured by using the methods described herein. Yet another embodiment provides a three-dimensional article including: a scaffolding material and a supporting material in a shape of a foamy layer coupled to the scaffolding material.

1 . A solid freeform fabrication method of creating a three-dimensional article built at least in part from scaffolding layers, the method comprising:
 providing a scaffolding material;   providing a supporting material in a shape of a foamy layer; and   contacting the scaffolding material with the foamy layer to form at least one scaffolding layer and thereby creating the three dimensional article.   
     
     
         2 . A three-dimensional article manufactured by using the method of  claim 1 . 
     
     
         3 . The three-dimensional article of  claim 2 , wherein the three dimensional article is an artificial tissue. 
     
     
         4 . The three-dimensional article of  claim 3 , wherein the scaffolding material is a member selected from the group consisting of alginate, chitosan, collagen, fibrin, salts and derivatives thereof. 
     
     
         5 . The three-dimensional article of  claim 3 , wherein the foaming agent is a member selected from the group consisting of anionic surfactants, cationic surfactants, amphoteric surfactants, non-ionic surfactants, hydrolyzed protein and fluorocarbon surfactants. 
     
     
         6 . The three-dimensional article of  claim 3 , wherein the supporting material further comprises at least one of a crosslinking agent, a surface modifier, a sterilizing agent, and a biologically active agent. 
     
     
         7 . The three-dimensional article of  claim 3 , wherein the biologically active agent is a member selected from the group consisting of cells, nucleic acids, proteins, and pharmacologically active agents. 
     
     
         8 . A three-dimensional article comprising:
 a scaffolding material; and   a supporting material in a shape of a foamy layer coupled to the scaffolding material.   
     
     
         9 . The three-dimensional article of  claim 8 , wherein the scaffolding material is deposited on a top outer surface of the foamy layer, inside the foamy layer or both. 
     
     
         10 . The three-dimensional article of  claim 8 , wherein the supporting material comprises a foaming agent. 
     
     
         11 . The three-dimensional article of  claim 8 , wherein the supporting material comprises a foaming agent and a crosslinking agent. 
     
     
         12 . The three-dimensional article of  claim 11 , wherein the foaming agent is a member selected from the group consisting of: anionic surfactants, cationic surfactants, amphoteric surfactants, non-ionic surfactants, hydrolyzed protein, and fluorocarbon surfactants. 
     
     
         13 . The three-dimensional article of  claim 11 , wherein the crosslinking agent is a member selected from the group consisting of: calcium chloride, barium chloride, thrombin, sodium hydroxide, and glutaraldehyde. 
     
     
         14 . The three-dimensional article of  claim 8 , wherein the scaffolding material is a member selected from the group consisting of: alginate, chitosan, collagen, fibrin, salts, and derivatives thereof. 
     
     
         15 . The three-dimensional article of  claim 8 , wherein the supporting material further comprises a biologically active agent. 
     
     
         16 . The three-dimensional article of  claim 15 , wherein the biologically active agent is a member selected from the group consisting of: cells, nucleic acids, proteins, and pharmacologically active agents. 
     
     
         17 . The three-dimensional article of  claim 8 , wherein the supporting material further comprises at lease one of a surface modifier or a sterilizing agent. 
     
     
         18 . The three-dimensional article of  claim 8 , wherein the supporting material is retained within the three-dimensional article.