Optimisation of Bioinspired Fibre Architectures for 3D-Printed Polymer Heart Valves via Melt Electrowriting (MEW) Using FE Modelling and Design of Experiments (FE-DOE).

Aortic stenosis is predominantly treated through transcatheter bioprosthetic heart valve implantation. However, the materials used in these devices are prone to premature failure. Polymer heart valves provide an alternative to current commercial devices, offering materials with greater durability and customisation through fibre reinforcement. Given the wide range of available materials and structures, there is a need for a systematic and efficient approach to designing and optimising novel bioinspired polymeric leaflets. This work presents a framework that employs computational modelling and Design of Experiments (DOE) tools to optimise bioinspired, 3D-printed, fibre-reinforced polymer leaflets made using melt electrowriting (MEW). Here, finite element (FE) models are created to represent MEW fibre-reinforced polymer leaflets for application in a transcatheter aortic heart valve. The behaviour of this valve under physiological loading conditions is modelled to predict valve performance and leaflet material response. These models were first used to investigate the impact of fibre orientation on valve performance and leaflet response, thereby demonstrating the benefits of a bioinspired fibre reinforcement structure. Using a DOE approach, the structural combination of MEW fibre reinforcement and an elastomeric matrix was optimised to improve valve performance and reduce leaflet stress and strain. Overall, the framework offers an efficient and versatile methodology for optimising fibre-reinforced polymer leaflets using an in silico approach, thereby reducing the need for physical prototyping and testing of these next-generation devices during early product development.