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

Abstract

Hernia repair is one of the most common procedures worldwise, with over 20 million performed every year, close to 1 million alone in the united states. Current off-the-shelf heria meshes are limited by fixed sizes, variable pore structures, and inconsistent conformity, contributing to higher recurrence, discomfort, and complication rates. However, hospitals experience significant waste when carrying various mesh types; unused or expired materials become wasted surgical supplies, thus significantly increasing cost. These challenges give rise to a clear clinical and economic opportunity for a customizable, on-demand hernia mesh solution.

This project aims to develop a patient-specific 3D-printed mesh fabricated by Masked Stereolithography (MSLA). This provides surgeons with the ability to enter patient-specific mesh dimensions and generate a mesh automatically optimized for mechanical stability, tissue integration, and ease of handling. Specific engineering parameters include: ≥50 N/cm suture retention strength, <5% recurrence at 12 months, pore size ≥75 μm (macroporous), mesh thickness 0.5 mm ± 0.01 mm, print resolution <200 μm, and density 35–60 g/m². These requirements are directly tied to customer needs of improved fit, reduced shrinkage, biocompatibility, and safe tissue integration.

Manufacturing considerations include resin selection, print accuracy, post-processing sterilization, and software automation. Cost modeling indicates the MSLA process can produce a custom mesh for $5–$8 in resin, supported by a $10,000 printer and standard wash/curing equipment. Compared to existing mesh costs ranging from $50 to $2,000, an on-demand printed mesh presents strong market viability.

This eBook demonstrates that customizable MSLA-printed hernia meshes have the potential to improve surgical precision, reduce hospital waste, and advance patient-specific medical manufacturing.

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