Mechanical properties and bioanalytical characterization for a novel non-toxic flexible photopolymer formulation class

We present herein a new class of resin formulations for stereolithography, named FlexSL, with a broad bandwidth of tunable mechanical properties. The novel polyether(meth)acrylate based material class has outstanding material characteristics in combination with the advantages of being a biocompatible (meth)acrylate based processing material. FlexSL shows very promising results in several initial biocompatibility tests. This emphasizes its non-toxic behavior in a biomedical environment, caused mainly by the (meth)acrylate based core components. A short overview of mechanical and processing properties will be given in the end. The herein presented novel FlexSL materials show a significant lower cytotoxicity in contrast to commercial applied acrylic stereolithography resins. Further biocompatibility tests according to ISO 10993 protocols are planned. On the one hand, there are technical applications for this material (e.g. flaps, tubes, hoses, cables, sealing parts, connectors and other technical rubber-like applications), and on the other hand, broad fields of potential biomedical applications in which the FlexSL materials can be beneficial are obvious. Especially these could be small series production of medical products with special flexible material requirements. In addition, the usage for individual soft hearing aid shells, intra-operative planning services and tools like intra-op cutting templates and sawing guides is very attractive. The possibility to modify the FlexSL resins also for high-resolution applications makes it possible to manufacture now very flexible micro-prototypes with outstanding material characteristics and very fine structures with a minimum resolution of 20 mym and a layer thickness of minimal 5 myrn. These resin formulations are applicable and adjustable to other stereolithographic equipment available on the market