The influence of manufacturing methods on the function and performance of a synthetic leaflet heart valve

Materials and manufacturing perspectives in engineering heart valves: a review

Valvular heart diseases (VHD) are a major health burden, affecting millions of people worldwide. The treatments for such diseases rely on medicine, valve repair, and artificial heart valves including mechanical and bioprosthetic valves. Yet, there are countless reports on possible alternatives noting long-term stability and biocompatibility issues and highlighting the need for fabrication of more durable and effective replacements. This review discusses the current and potential materials that can be used for developing such valves along with existing and developing fabrication methods. With this perspective, we quantitatively compare mechanical properties of various materials that are currently used or proposed for heart valves along with their fabrication processes to identify challenges we face in creating new materials and manufacturing techniques to better mimick ​the performance of native heart valves.

Mechanical considerations for polymeric heart valve development: Biomechanics, materials, design and manufacturing

The native human heart valve leaflet contains a layered microstructure comprising a hierarchical arrangement of collagen, elastin, proteoglycans and various cell types. Here, we review the various experimental methods that have been employed to probe this intricate microstructure and which attempt to elucidate the mechanisms that govern the leaflet's mechanical properties. These methods include uniaxial, biaxial, and flexural tests, coupled with microstructural characterization techniques such as small angle X-ray scattering (SAXS), small angle light scattering (SALS), and polarized light microscopy. These experiments have revealed complex elastic and viscoelastic mechanisms that are highly directional and dependent upon loading conditions and biochemistry. Of all engineering materials, polymers and polymer-based composites are best able to mimic the tissue-level mechanical behavior of the native leaflet. This similarity to native tissue permits the fabrication of polymeric valves with physiological flow patterns, reducing the risk of thrombosis compared to mechanical valves and in some cases surpassing the in vivo durability of bioprosthetic valves. Earlier work on polymeric valves simply assumed the mechanical properties of the polymer material to be linear elastic, while more recent studies have considered the full hyperelastic stress-strain response. These material models have been incorporated into computational models for the optimization of valve geometry, with the goal of minimizing internal stresses and improving durability. The latter portion of this review recounts these developments in polymeric heart valves, with a focus on mechanical testing of polymers, valve geometry, and manufacturing methods.

Characterization of mechanical properties of pericardium tissue using planar biaxial tension and flexural deformation

Flexure is an important mode of deformation for native and bioprosthetic heart valves. However, mechanical characterization of bioprosthetic leaflet materials has been done primarily through planar tensile testing. In this study, an integrated experimental and computational cantilever beam bending test was performed to characterize the flexural properties of glutaraldehyde-treated bovine and porcine pericardium of different thicknesses. A strain-invariant based structural constitutive model was used to model the pericardial mechanical behavior quantified through the bending tests of this study and the planar biaxial tests previously performed. The model parameters were optimized through an inverse finite element (FE) procedure in order to describe both sets of experimental data. The optimized material properties were implemented in FE simulations of transcatheter aortic valve (TAV) deformation. It was observed that porcine pericardium TAV leaflets experienced significantly more flexure than bovine when subjected to opening pressurization, and that the flexure may be overestimated using a constitutive model derived from purely planar tensile experimental data. Thus, modeling of a combination of flexural and biaxial tensile testing data may be necessary to more accurately describe the mechanical properties of pericardium, and to computationally investigate bioprosthetic leaflet function and design.

Computational modeling of cardiac valve function and intervention

In the past two decades, major advances have been made in the clinical evaluation and treatment of valvular heart disease owing to the advent of noninvasive cardiac imaging modalities. In clinical practice, valvular disease evaluation is typically performed on two-dimensional (2D) images, even though most imaging modalities offer three-dimensional (3D) volumetric, time-resolved data. Such 3D data offer researchers the possibility to reconstruct the 3D geometry of heart valves at a patient-specific level. When these data are integrated with computational models, native heart valve biomechanical function can be investigated, and preoperative planning tools can be developed. In this review, we outline the advances in valve geometry reconstruction, tissue property modeling, and loading and boundary definitions for the purpose of realistic computational structural analysis of cardiac valve function and intervention.

Recent Advances in Polymeric Heart Valves Research

Heart valve replacement is fast becoming a routine surgery worldwide, and heart valve prostheses are today considered among the most widely used cardiovascular devices. Mechanical and bioprostheses have been the traditional choices to the replacement surgeries. However, such valves continue to expose patients to risks including thrombosis, infection and limited valve durability. In recent years, advances in polymer science give rise to an important new class of artificial heart valve made predominantly of polyurethane-based materials, which show improved biocompatibility and biostability. These polymeric heart valves have demonstrated excellent hemodynamic performance and good durability with excellent fatigue stress resistance. Advancements in the designs and manufacturing methods also suggested improved in the durability of polymeric heart valves. Animal studies with these valves have also shown good biocompatibility with minimal calcification of the valve leaflets. With these promising progresses, polymeric heart valves could be a viable alternative in the heart valve replacement surgeries in the near future.

Design of a novel polymeric heart valve

Polymeric heart valves could offer an optimum alternative to current prostheses, by joining the advantages of mechanical and bioprosthetic valves. Though a number of materials suitable for this application have recently become available, significant improvements in the valve design are still needed. In this paper, a novel polymeric heart valve design is proposed and its optimization procedure, based on the use of finite elements, is described. The design strategy was aimed at reducing the energy absorbed during the operating cycle, resulting in high hydrodynamic performances and reduced stress levels. The efficacy of the design strategy was assessed by comparing the valve dynamics and stress levels predicted numerically during the cycle with those of an existing and well qualified polymeric valve design. The improved hydrodynamic performance of the proposed design was confirmed experimentally, by in vitro testing in a pulse duplicator.

Polymeric heart valves: new materials, emerging hopes

Heart valve (HV) replacements are among the most widely used cardiovascular devices and are in rising demand. Currently, clinically available devices are restricted to slightly modified mechanical and bioprosthetic valves. Polymeric HVs could represent an attractive alternative to the existing prostheses, merging the superior durability of mechanical valves and the enhanced haemodynamic function of bioprosthetic valves. After early unsatisfactory clinical results, polymeric HVs did not reach commercialization, mainly owing to their limited durability. Recent advances in polymers, nanomaterials and surface modification techniques together with the emergence of novel biomaterials have resulted in improved biocompatibility and biostability. Advances in HV design and fabrication methods could also lead to polymeric HVs that are suitable for long-lasting implantation. Considering all these progresses, it is likely that the new generation of polymeric HVs will find successful long-term clinical applications in future.

Fluid Dynamic Assessment of Three Polymeric Heart Valves Using Particle Image Velocimetry

Polymeric heart valves have the potential to reduce thrombogenic complications associated with current mechanical valves and overcome fatigue-related problems experienced by bioprosthetic valves. In this paper we characterize the in vitro velocity and Reynolds Shear Stress (RSS) fields inside and downstream of three different prototype trileaflet polymeric heart valves. The fluid dynamic differences are then correlated with variations in valve design parameters. The three valves differ in leaflet thickness, ranging from 80 to 120 mum, and commisural design, either closed, opened, or semi-opened. The valves were subjected to aortic flow conditions and the velocity measured using three-dimensional stereo Particle Image Velocimetry. The peak forward flow phase in the three valves was characterized by a strong central orifice jet of approximately 2 m/s with a flat profile along the trailing edge of the leaflets. Leakage jets, with principle RSS magnitudes exceeding 4,500 dyn/cm(2), were observed in all valves with larger leaflet thicknesses and also corresponded to larger leakage volumes. Additional leakage jets were observed at the commissural region of valves with the open and the semi-open commissural designs. The results of the present study indicate that commissural design and leaflet thickness influence valve fluid dynamics and thus the thrombogenic potential of trileaflet polymeric valves.

Design and manufacture of a polyvinyl alcohol (PVA) cryogel tri-leaflet heart valve prosthesis

Although current artificial heart valves are life sustaining medical devices, improvements are still necessary to address deficiencies. Bioprosthetic valves have a compromised fatigue life, while mechanical valves have better durability but are prone to thromboembolic complications. A novel, one-piece, tricuspid valve, consisting of leaflets, stent and sewing ring, made entirely from the hydrogel, polyvinyl alcohol cryogel (PVA-C), has been developed and demonstrated. This valve has three thin leaflets attached to a cylindrical stent. In order to approximate the complex shape of the surface of the natural heart valve leaflets, two different geometries have been proposed: revolution about an axis of a hyperboloid shape and revolution about an axis of an arc subtending (joining) two straight lines. The parameters of both geometries were examined based on a compromise between avoiding sharp curvature of leaflets and minimization of the central opening of the valve when closed. The revolution of an arc subtending two straight lines was selected as the preferred geometry since it has the benefit of a smaller central opening when the value of the maximum curvature for the leaflets is the same for each valve geometry. A cavity mold has been designed and constructed to form the PVA-C heart valve. The three leaflets were formed and integrated into the stent and sewing ring in a single process. Prototype heart valves were manufactured in the mold from a solution of PVA and water, by controlled freezing and thawing cycles.

A synthetic fiber-reinforced stentless heart valve

There is strong evidence that failure of bioprosthetic and synthetic valves occurs as a consequence of high tensile and bending stresses, acting on the leaflets during opening and closing. In stented prostheses, whether synthetic or biological, the absence of contraction of the aortic base causes the leaflets to be subjected to an unphysiological degree of flexure, which is also related to calcification. However, a stentless synthetic valve, which has a flexible aorta base, can be a good alternative for stented synthetic valves. Moreover, fiber-reinforcement is assumed to lead to a decrease of tears and perforation as a result of reduced stresses in the weaker parts of the leaflets in their closed configuration. The manufacturing method for a stentless, fiber-reinforced, synthetic valve is presented. Prototypes are tested in a pulse duplicator system. The results show that the mean systolic pressure difference is very low, while the high regurgitation (up to 26%) is probably caused by a too small coaptation area of the leaflets.

A three-dimensional mechanical analysis of a stentless fibre-reinforced aortic valve prosthesis

Failure of bioprosthetic and synthetic three-leaflet valves has been shown to occur as a consequence of high tensile and bending stresses, acting on the leaflets during opening and closing. Moreover, in the stented prostheses, whether synthetic or biological, the absence of contraction of the aortic base, due to the rigid stent, causes the leaflets to be subjected to an unphysiological degree of flexure, which is related to calcification. It is shown that the absence of the stent, which gives a flexible aortic base and leaflet attachment, and leaflet fibre-reinforcement result in reduced stresses in the weaker parts of the leaflets in their closed configuration. It is postulated that this leads to a decrease of tears and perforations, which may result in a improved long-term behaviour. The effect of a flexible leaflet attachment and aortic base of a synthetic valve is investigated with a finite element model. Different fibre-reinforced structures are analysed with respect to the stresses that are likely to contribute to the failure of fibre-reinforced prostheses and compared with the results obtained for a stented prosthesis. Results show that for the stentless models a reduction of stresses up to 75% is obtained with respect to stented models with the same type of reinforcement.

Investigation of unsteady flow in a model of a ventricular assist device by numerical modelling and comparison with experiment

Prior to this study, a clinical prototype of a sac-type ventricular assist device (VAD) was investigated experimentally, using both flow visualisation and Laser Doppler anemometry (LDA), in order to optimise its geometry. As poor optical access precluded the experimental investigation of the flow in some areas of the prototype VAD, computational fluid dynamics (CFD) was used in the present work. Flow patterns during one full pumping cycle were investigated in a simplified model of the VAD. The numerical solutions were compared with experimental results from an identical physical model. The model consists of the hemispherical cylinder and two attached tubes for the inflow and outflow. Instead of a diaphragm in the clinical device, which deforms non-uniformly during pumping, a piston with a matching hemispherical crown was used. A finite volume method was employed to solve the governing equations for the three-dimensional, unsteady, laminar flow of an incompressible, Newtonian fluid. The general flow features were predicted very well by the simulation, with some differences in the details of the flow structures. This allows the conclusion that CFD can be used to facilitate improvement of the design of the clinical device. The comparison of one-component velocity time histories at selected points showed that the predicted velocities were approximately 20-50% lower than those measured by LDA. Such underprediction would lead to erroneous results for particle residence times and may result in an underestimation of wall shear stresses.

Finite element stress analysis of a new design of synthetic leaflet heart valve

This paper presents a parametric finite element analysis of the stresses in the leaflets of a new design of polyurethane heart valve in the closed position. The alpharabola geometry of the valve has previously been reported by Leat and Fisher (1) and has been shown to demonstrate good opening characteristics. The effects of variations in leaflet offset parameter, g, length, h, and local thickening have been determined for a valve where the frame is assumed rigid. A spherical leaflet geometry has also been analysed for comparative purposes. Results have shown that the alpharabola leaflet geometry can reduce the maximum principal tensile stress to 60 per cent of that for a spherical valve of the same mesh density.

In vitro determination of the curvatures and bending strains acting on the leaflets of polyurethane trileaflet heart valves during leaflet motion

Leaflet tears originating from the free leaflet edge and calcification around the commissural region are common modes of failure exhibited by explanted bioprosthetic trileaflet heart valves. These may be a result of the cyclic bending and high levels of curvature that affect the leaflets within these areas during normal valve operation. These high levels of curvature occur in a short time period (approximately 20 ms) during rapid leaflet opening and to a lesser degree during leaflet closure. The curvatures that occur at the free leaflet edge of two designs of polyurethane trileaflet heart valve were determined in vitro at various stages during a cardiac cycle using a high-speed video camera (1000 frames/s). Significant deformations at the free leaflet edge were observed and bending radii as low as 0.55 +/- 0.125 mm (mean +/- standard deviation) were present during leaflet opening, 0.76 +/- 0.24 mm during leaflet closure and 1.01 +/- 0.27 mm while the valve was fully open during peak systole. The values of curvature were used to determine the values of bending strain and bending stress acting at the free leaflet edge using thin shell bending theory. The calculated values of bending strain were a maximum during the leaflet flexure associated with valve opening. These high levels of bending strain, which occur for short periods of time, are likely to be an important determinant of the valve's durability. It has been shown that the method of manufacture significantly influenced the level of bending strain in the valve leaflets. Valves manufactured using a dip-casting technique resulted in open leaflet bending strains up to 31 per cent lower than valves manufactured from solvent-cast sheets of polyurethane.