Enhanced Additive Manufacturing Systems for Medical Devices

Publication ID: 24-11857735_0006_PTD

Published: October 28, 2025

Category:Direct Improvements & Enhancements

Legal Citation

pr1or.art Inc., “Enhanced Additive Manufacturing Systems for Medical Devices,” Published Technical Disclosure No. 24-11857735_0006_PTD, Published October 28, 2025, available at https://archive.pr1or.art/24-11857735_0006_PTD

This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,735.

Summary of the Inventive Concept

The inventive concept relates to advanced additive manufacturing systems for producing medical devices, such as catheters and implantable stimulation leads, with improved material flow, reduced warping, and tailored properties.

Background and Problem Solved

The original patent disclosed additive manufacturing systems for medical devices, but had limitations in terms of material flow, warping, and property control. The new inventive concept addresses these limitations by introducing adjustable temperature control, concurrent deposition of multiple filaments, and integrated steering capability.

Detailed Description of the Inventive Concept

The new system comprises a filament feeder with adjustable temperature control to facilitate improved material flow and reduced warping of the printed device. Additionally, the system enables concurrent deposition of multiple filaments with varying stiffness and color at varying blend ratios to produce a device with tailored flex modulus and visual characteristics. Furthermore, the system integrates a 3D printing module with pull wires, allowing for space-efficient construction and improved handling properties. The inventive concept also enables the production of catheter jackets with enhanced lubricity by depositing a lubricious material onto the outer surface during the 3D printing process.

Novelty and Inventive Step

The new inventive concept introduces novel features such as adjustable temperature control, concurrent deposition of multiple filaments, and integrated steering capability, which are not present in the original patent. These features provide a non-obvious solution to the limitations of the original patent.

Alternative Embodiments and Variations

Alternative embodiments of the inventive concept could include using different types of filaments, varying the temperature control, or integrating additional features such as sensors or actuators. Variations of the system could be used to produce other types of medical devices, such as implantable sensors or surgical instruments.

Potential Commercial Applications and Market

The inventive concept has significant commercial potential in the medical device industry, particularly in the areas of catheters, implantable stimulation leads, and other medical devices that require tailored properties and precise manufacturing. The target market includes medical device manufacturers, hospitals, and research institutions.

CPC Classifications

Section	Class	Group
A	A61	A61M25/0012
B	B29	B29C64/118
B	B29	B29C64/209
B	B29	B29C64/295
B	B29	B29C64/336
B	B29	B29C64/393
B	B33	B33Y10/00
B	B33	B33Y30/00
B	B33	B33Y40/00
B	B33	B33Y50/02
B	B33	B33Y80/00
A	A61	A61N1/05
B	B29	B29K2995/007
B	B29	B29L2031/7542

Section 103 Obviousness Analysis (PHOSITA)

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Field of Art

Medical Device Manufacturing, Additive Manufacturing, and 3D Printing Technologies with a focus on medical device fabrication, particularly catheters and implantable leads

Person of Ordinary Skill (PHOSITA) Profile

A skilled practitioner with expertise in materials engineering, 3D printing techniques, medical device design, and polymer processing, typically holding an advanced degree in biomedical engineering or materials science with 3-5 years of specialized experience in medical device manufacturing

Obviousness Rationale

A person having ordinary skill in the art would recognize that the PTD's variations represent predictable extensions of the source patent's core additive manufacturing methodology. The disclosed improvements in filament deposition, temperature control, and material blending are logical refinements to the existing 3D printing approach for medical devices. These modifications represent incremental advancements that would be apparent to a skilled practitioner seeking to optimize manufacturing processes and device characteristics.

Obvious Combinations & Variations

Source Patent Element

Heating cartridge with substrate inlet and outlet ports for 3D printing medical devices

PTD Variation

Filament feeder with adjustable temperature control to improve material flow and reduce warping

Obviousness Reasoning

A PHOSITA would recognize temperature control as a known technique for optimizing polymer processing, with predictable results in improving material characteristics during additive manufacturing

Source Patent Element

Elongate substrate for catheter manufacturing with particulate near outer surface

PTD Variation

Depositing lubricious material onto catheter jacket surface during 3D printing process

Obviousness Reasoning

Surface modification of medical devices is a well-established technique, and a skilled practitioner would find it obvious to enhance catheter properties by incorporating lubricious materials during fabrication

Source Patent Element

Additive manufacturing system for medical devices with multiple processing parameters

PTD Variation

Concurrent deposition of multiple filaments with varying stiffness and color at different blend ratios

Obviousness Reasoning

Material blending and multi-material printing are known techniques in additive manufacturing, and a PHOSITA would recognize the predictable benefit of creating composite devices with tailored mechanical properties

Source Patent Element

3D printing system for medical device fabrication

PTD Variation

Integrated 3D printing module with pull wires for improved steering and handling properties

Obviousness Reasoning

Incorporating additional functional elements into medical device manufacturing is a standard design approach, and a skilled practitioner would find it obvious to enhance device capabilities through integrated structural modifications

Source Patent Element

Catheter manufacturing using additive manufacturing with specific material properties

PTD Variation

Creating composite materials with unique combinations of electrical conductivity and thermal insulation

Obviousness Reasoning

Material property engineering is a predictable extension of existing manufacturing techniques, and a PHOSITA would recognize the potential for creating multi-functional medical devices through strategic material selection

35 U.S.C. § 103 Summary: Based on the teachings of US Patent 11857735 and the published technical disclosure, a person having ordinary skill in the art would find the claimed variations obvious, as they represent predictable refinements to existing additive manufacturing methodologies for medical devices. The disclosed innovations constitute obvious combinations of known techniques in materials processing, device fabrication, and functional enhancement, thereby rendering potential patent claims obvious and anticipatable as prior art.

Original Patent Information

Patent Number	US 11,857,735
Title	Systems and methods for manufacturing 3D printed medical devices
Assignee(s)	Medtronic, Inc.