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This white paper describes a cardiac-specific workflow integrating 3D printing and silicone molding based on patient-derived CT angiography data to create left ventricular models for device development and procedural simulation. Material jetting 3D printing was used to mimic myocardial compliance, while stereolithography molds were designed to cast transparent silicone models. These models can be used for pre-procedural device sizing and positioning of mechanical circulatory support (MCS) devices like Impella or LVADs.
Patient-specific 3D-printed and silicone left ventricular models can improve pre-procedural planning and simulation for MCS device deployment, potentially reducing complications and improving outcomes.
Three-dimensional (3D) anatomic modeling derived from high-resolution medical imaging, such as computed tomography (CT) and magnetic resonance imaging (MRI), has been increasingly adopted in preclinical testing and device development. This white paper describes a cardiac-specific workflow that integrates 3D printing and silicone molding for support device development and procedural simulation. Patient-derived computed tomography angiography data were segmented using FDA-cleared medical modeling software to isolate the left ventricular anatomy and were further processed in computer-aided design (CAD) to ensure accurate physiological wall thickness and structural fidelity. Material jetting 3D printing was performed on a Stratasys J750 using material distributions designed to mimic the mechanical properties of myocardium, thereby approximating myocardial compliance. In parallel, stereolithography apparatus molds were designed from the left ventricle CAD model to cast transparent, pliable left ventricular models in Sorta-Clear™ 18 silicone. The 3D-printed models preserved intricate morphological detail and were suitable for mechanical manipulation and device deployment studies, whereas silicone models offered tunable mechanical properties, transparency for visualization, and durability for repeated use. Together, these complementary modalities provided rapid manufacturing capability and application-relevant physical representation. Case-specific parameters, strengths, and limitations of both models in enhancing patient care and device testing are highlighted, with relevance to heart failure applications. Current knowledge gaps, workflow and integration challenges, and future opportunities are identified, positioning this work as a reference framework for continued innovation in anatomic modeling. Within the collaborative framework of Mayo Clinic's Anatomic Modeling Unit and Simulation Center, this integrated modeling workflow demonstrates the value of multidisciplinary collaboration between engineers and clinicians. Clinically, these patient-specific left ventricular models may enable pre-procedural device sizing and positioning and may support simulation of mechanical circulatory support (MCS) deployment while identifying possible anatomic constraints prior to intervention. This workflow has direct applicability in advanced heart failure patients undergoing MCS support, such as the Impella axillary MCS device or the durable LVAD, with potential to reduce procedural uncertainty while reducing complications and improving peri-procedural outcomes. Additionally, these models also serve as high-accuracy educational tools, enabling trainees and multidisciplinary care teams to visualize and possibly rehearse procedural steps while gaining hands-on experience in a risk-free environment.
