3D Printing of Polyvinyl Alcohol for Meniscus Implant Fabrication

Meniscectomy is a common surgical procedure to treat meniscal injuries, but it often leads to long-term complications such as osteoarthritis. Polyvinyl alcohol (PVA) hydrogel implants offer a promising alternative due to their viscoelastic properties, which closely mimic the natural meniscus. However, conventional manufacturing methods rely on manual shaping, which limits precision and customization. This study explores the feasibility of 3D printing PVA hydrogels by direct ink writing (DIW) for patient-specific meniscus implants. A syringe-based extrusion system was developed and printing parameters were optimized using a factorial design experiment, evaluating the effects of speed and flow rate on dimensional accuracy and layer scaling. In addition, tensile tests and post-treatments, including autoclaving, demonstrated that the printed PVA structures could achieve mechanical properties comparable to those of native meniscus. In addition, a molding method validated the formation of meniscus-shaped structures with shock absorption capabilities. Future research should focus on refining printing methods that provide structural support during fabrication to achieve reliable 3D architectures. This work demonstrates the potential of 3D printed PVA hydrogels for meniscal replacement, offering a possible approach for the manufacture of customized implants.