On-Demand Customizable Manufacturing of Hernia Repair Meshes: Feasibility of 3D Printing with MSLA

Abstract

Hernia repair is one of the most common surgical procedures with over 20 million performed each year worldwide. Current meshes are supplied in limited sizes, requiring pre-operative trimming and creating unnecessary inventory surplus. These limitations increase the risk of recurrence, post-operative complications, and patient discomfort. Additionally hospitals face excess waste and financial losses from unused/expired inventory.

This project proposes a rapid on-demand 3D printed patient-specific hernia mesh using masked stereolithography (MSLA) technology. By integrating automated design software with on-demand manufacturing capabilities, surgeons can input patient-specific anatomical parameters into the program to generate a customized mesh design optimized for tissue reintegration, mechanical integrity, and surgical handling by targeting key specifications such as controlled strand width, thickness, and pore size.

Prototyping demonstrated consistent thickness (0.4 mm ± 0.1 mm) and macroporous architecture (1-3.5 mm) were tested, although dimensional deviations increased as pore size decreased. The entire design to print cycle for a 5×5 cm mesh was ≤8 minutes and consistently maintained mesh dimensions. Virtual prototyping identified the need for increased structural strength. Total costs, including equipment/manufacturing, are estimated to equal $1,246.45. The manufacturing price per mesh is ~$2, compared to competitor’s $50-2000 price per mesh.

This demonstrates the feasibility of a rapid, on-demand workflow for producing patient-specific hernia mesh and supports future research into improved mechanical performance. With an on-demand, patient-specific device, hospitals will minimize their waste and decrease costs while increasing patient satisfaction. This technology demonstrates a strong pathway toward commercialization and increased potential for clinical implementation.

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