Layered manufacturing utilizing foam as a support and multifunctional material for the creation of parts and for tissue engineering
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.
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. The method of claim 1 , wherein the scaffolding material is deposited on a top outer surface of the foamy layer, inside the foamy layer or both.
3. The method of claim 1 , wherein the supporting material comprises a foaming agent.
4. The method of claim 1 , wherein the supporting material comprises a foaming agent and a crosslinking agent.
5. The method of claim 4 , 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 method of claim 4 , wherein the crosslinking agent is a member selected from the group consisting of calcium chloride, barium chloride, thrombin, sodium hydroxide and glutaraldehyde.
7. The method of claim 1 , wherein the scaffolding material is a member selected from the group consisting of alginate, chitosan, collagen, fibrin, salts and derivatives thereof.
8. The method of claim 1 , wherein the supporting material further comprises a biologically active agent.
9. The method of claim 8 , wherein the biologically active agent is a member selected from the group consisting of cells, nucleic acids, proteins, and pharmacologically active agents.
10. The method of claim 1 , wherein the supporting material further comprises at least one of a surface modifier or a sterilizing agent.
11. The method of claim 1 , further comprising depositing the supporting material simultaneously with the scaffolding material such that the supporting material is retained within the three dimensional article.
12. The method of claim 11 , wherein the supporting material comprises a foaming agent, a crosslinking agent and optionally a biologically active agent.
13. The method of claim 12 , wherein the supporting material further comprises at least one of a surface modifier or a sterilizing agent.
14. The method of claim 1 , wherein the foamy layer acts as a cooling media for the scaffolding material.