Beyond decoration: free-standing lace embroidery for 3D shaped surgical mesh implants
Robert Tonndorf, Cindy Elschner, Alice Osterberg, Victor Mozer, Eduardo Antonio Wink de Menezes, Lilly Römer, Yordan Kyosev, Axel Spickenheuer, Christina Scheffler, Markus Stommel
TL;DR
This paper introduces a new method using lace embroidery to create 3D surgical mesh implants that fit better and are more robust.
Contribution
The study introduces free-standing lace embroidery as a novel technique for creating 3D surgical mesh implants with precise pore geometries.
Findings
Embroidered mesh pockets are mechanically robust and conform well to curved surfaces.
The method allows scalable production of implant shapes with minimal wrinkling.
Standard embroidery machines can be used to create patient-specific implants.
Abstract
Conventional mesh pockets manufactured from flat textiles by cutting and sewing often display wrinkles, excess material, and suboptimal fit on curved surfaces. This study demonstrates that free-standing lace embroidery enables the production of near-net-shape hemispherical mesh pockets with predefined pore geometries using standard embroidery machines. These pockets are scalable to different implant sizes and shapes. Experimental evaluations, including tensile and drop testing as well as 3D surface scanning, confirmed that the pockets are mechanically robust and exhibit excellent conformity with minimal wrinkling. These results highlight the potential of embroidery as a versatile platform for developing patient-specific surgical mesh implants. The online version contains supplementary material available at 10.1038/s41598-026-36575-2.
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Taxonomy
TopicsAdvanced Materials and Mechanics · 3D Shape Modeling and Analysis · Structural Analysis and Optimization