Advanced Design Methodologies for Additive Manufacturing in Patient-Specific Medical Solutions

A special issue of Designs (ISSN 2411-9660). This special issue belongs to the section "Bioengineering Design".

Deadline for manuscript submissions: 31 May 2026 | Viewed by 148

Special Issue Editors


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Guest Editor
Department of Engineering, University of Perugia, 06125 Perugia, Italy
Interests: mechanical engineering; design methods for industrial engineering; biomechanics; multibody; finite elements
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Department of Engineering, University of Perugia, 06125 Perugia, Italy
Interests: manufacturing engineering; additive manufacturing; bioprinting; process optimization, monitoring and control; AI for manufacturing and metrology

Special Issue Information

Dear Colleagues,

Optimizing design parameters is essential when a device is required to interact with the human body, especially if additive manufacturing is used; indeed, 3D printing and bioprinting has enabled the possibility of manufacturing almost any shape using a wide choice of materials.

Automated methodologies are viable tools for creating innovative designs: topology optimization, predictive modelling, and inverse design are powerful techniques which, taking inspiration from nature, enable designs that can interact and integrate with the human body. However, a gap still exists between the designed CAD models and the printed structures. Bridging this gap requires new design approaches that consider both printability and the final device's characteristics.

Nonetheless, defining general design rules for AM-specific devices is very challenging, as outcomes depend on shape, material, and 3D printing process. Setting up clear and innovative procedures is a central step in moving towards complete integration in clinical practice; therefore, this Special Issue is focused on design methodologies for improving the performances of customized medical systems, looking at innovative technologies and materials, and trying to gather knowledge in view of regulatory design frameworks. Possible topics may include, but are not limited to, the following:

  • Design methodologies for 3D-printed and bioprinted medical devices;
  • Topology optimization and generative design for biomedical applications;
  • Predictive modeling and simulation for human–device interaction;
  • Inverse design strategies for personalized healthcare solutions;
  • Design for smart bioprinting;
  • Material selection and multi-material design considerations;
  • Printability-aware design and process–structure–property integration;
  • Standards and regulatory frameworks for AM-based medical devices.

We look forward to receiving your contributions to this Special Issue.

Dr. Giulia Pascoletti
Dr. Arianna Rossi
Guest Editors

Manuscript Submission Information

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Keywords

  • design optimization
  • bioinspired design
  • generative design
  • process design
  • topology optimization
  • customized devices
  • biomedical devices
  • medical devices regulations
  • additive manufacturing
  • bioprinting

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Published Papers (1 paper)

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Research

14 pages, 1870 KB  
Article
Development and Mechanical Evaluation of a Stent Graft for Endovascular Aneurysm Repair Using Finite Element Modeling
by Athanasios Konstantakopoulos, Nikolaos Kladovasilakis and Georgios E. Stavroulakis
Designs 2025, 9(5), 103; https://doi.org/10.3390/designs9050103 - 1 Sep 2025
Abstract
An abdominal aortic aneurysm (AAA) poses a significant risk of arterial wall rupture, which critically endangers the patient’s life. To address this condition, an endovascular aneurysm repair (EVAR) is required, involving the insertion and expansion of a stent-graft within the aorta, to support [...] Read more.
An abdominal aortic aneurysm (AAA) poses a significant risk of arterial wall rupture, which critically endangers the patient’s life. To address this condition, an endovascular aneurysm repair (EVAR) is required, involving the insertion and expansion of a stent-graft within the aorta, to support and isolate the weakened vessel wall. In this context, this article aims to approach the problem from a mechanical perspective and to simulate the expansion and deployment procedure realistically, utilizing the Finite Element Analysis (FEA). The process initiates with the computation evaluation of the aortic structure in order to identify critical regions of stress and strain in an aneurysmatic aortic region. Then, a customized 3D-designed stent graft model was developed for the aorta and positioned properly. Applying all the necessary boundary conditions, a complex nonlinear FEA was conducted until the stent-graft expanded radially, reaching a final diameter 25% larger than the aorta’s vessel wall while withstanding mean stress and strain values close to 400 MPa and 1.5%, respectively. Finally, the mechanical behavior of the stent-graft and its interaction with the internal aortic wall, during the expansion process, was evaluated, and the extracted results were analyzed. Full article
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