# Woven solutions for tissue engineering: Next-generation heart valves from fiber to function

## TL;DR

This paper presents a new method for creating heart valve implants using advanced textile weaving techniques, allowing for patient-specific designs with improved mechanical performance.

## Contribution

The novel contribution is the use of 3D weaving and CAD-based workflows to produce customizable, anatomically accurate heart valves with integrated functional zones.

## Key findings

- Multilayer weaving allows creation of heart valves with tailored mechanical properties in different zones.
- A CT-based digital workflow enables scalable production of patient-specific valve prostheses.
- Mechanical evaluations show improved performance compared to conventional valve designs.

## Abstract

Cardiovascular diseases remain one of the leading causes of morbidity and mortality worldwide, yet the availability of durable, patient-specific heart valve replacements is still limited. The aim is to utilize a biomimetic, textile-based design to mimic natural tissues, thereby creating customizable solutions with improved mechanical properties and scalable production for cardiovascular applications.

By leveraging advanced 3D weaving techniques, the feasibility of manufacturing anatomically adaptable and mechanically robust textile valves is demonstrated. CAD-based design workflows and functional materials such as shape memory Nitinol wires are part of this technology. The integration of form-defining geometries, multilayer structures and functional surface treatments is enabled through tailored binding design and machine adaptations.

A textile-based heart valve implant was developed using advanced 3D weaving, CAD modelling and patient-specific imaging. Integrated leaflets and an annular ring were formed directly during weaving using mold inserts and multilayer structures, eliminating post-processing. Polyester and Nitinol materials provided mechanical stability and shape-memory functionality. Simulation models and SPH analysis validated pressure behaviour and deformation under physiological conditions. Functional zones with tailored stiffness, sealing and mobility were realized through binding variation and Jacquard control. A reproducible digital workflow, from CT segmentation to weaving on modified looms, enabled scalable production of anatomically accurate, functionally optimized heart valve prostheses. Mechanical evaluations reveal favourable performance in comparison to conventional valve designs.

These findings highlight the potential of fiber and textile technology as a scalable, customizable clinically relevant platform for heart valve tissue engineering and future biomedical applications.

•Multilayer weaving enables integrated zones with tailored mechanical properties•Bicuspid and tricuspid walves can be woven in a single multilayer weaving process•Hierarchical tissue architecture is mimicked via targeted textile structure design•CT-based workflow allows fully patient-specific heart valve prothesis design•Custom weaving and simulation enable precise control over valve leaflet dynamics

Multilayer weaving enables integrated zones with tailored mechanical properties

Bicuspid and tricuspid walves can be woven in a single multilayer weaving process

Hierarchical tissue architecture is mimicked via targeted textile structure design

CT-based workflow allows fully patient-specific heart valve prothesis design

Custom weaving and simulation enable precise control over valve leaflet dynamics