Contactless Measurement of Integrity of Silicone Coating on Self-Expandable Esophageal Nitinol Stents

OBJECTIVES

A stent is a mesh tube inserted into a natural passage in the body to prevent disease induction. Self-expandable esophageal nitinol stents such as SX-ELLA Stent Esophageal HV (HV Stent Plus) can be indicated for palliation of malignant esophageal strictures, for the treatment of benign esophageal strictures that are refractory to standard therapy and for the treatment of esophago-respiratory fistulas. A silicone-stent coating is used for tumor in-growth prevention and esophago-respiratory fistula occlusion. The thickness of the stent and the overall integrity of the silicone coating of all wires indicate the overall mechanical properties of the esophageal stent and the resistance to external adverse events such as corrosion and mechanical and chemical resistance.

METHODS

The polymer multicomponent epoxy resin - a mixture of Epon and Durcupan - was used as a method for robust sample stabilization. A cutting system using a thin water beam with a powder (Blue Line) was chosen as the best variant to obtain 6 samples for both-sided measurement (10 measuring sides). The optical microscopic reflective light method was used to examine wire crossing points in the sections. Fifty values were measured on either sample side for the internal, external and mesh thickness of the silicone stent layer. The wire crossing points were selected so that the silicone layer structure could be clearly seen, and the wires approached each other most closely. Only approximately 4 to 8 crossing points in each section could be measured when applying this approach. The resolution of the microscope and calibration (based on the camera used) was 0.677 μm/pixel.

RESULTS

Additional data could be obtained on 8 planes. Two boundary samples were destroyed by the cutting process. Whole coating of the stent was around all mesh wires, especially in areas with higher mechanical stress (wire crossing). The minimum detectable and admissible value determined for all 3 measuring areas (internal, external, mesh) on the wire crossings was 6.77 μm, i.e., 10 pixels, based on the microscope resolution and manufacturer's methodology. The results were characterized by p < 0.001 for all 3 parameters. We tested opposite samples in each section to verify the section quality and data consistency. For the 4 areas, the data were significantly different, but the thickness differences were only on the order of units percent, so the measurements were not appreciably affected. We assume that the material cutting loss, making up 1-2 mm, contributed to the differences in the sections.

CONCLUSION

We examined the overall integrity of the silicone coating of the esophageal stent. The method of HV stent anchoring in a polymeric bath followed by cutting with a waterjet and sample measurement under an optical microscope proved to be very simple and reliable. Sufficient thicknesses of the silicone layer on the wire cross sections were verified. The coated silicone layer thickness appeared to be significantly different along the stent from the proximal part to the distant part, presumably due to the manufacturing technology.

Ultrastable and Durable Silicone Coating on Polycarbonate Surface Realized by Nanoscale Interfacial Engineering

Delamination of coating layer from polymer substrate limits the lifetime and functionality of the protective films. Silicone coating is especially vulnerable to photo irradiation, hydrothermal degradation, and mechanical deformation due to the low interfacial adhesion and mechanical robustness. Herein, an ingenious approach is developed to fabricate ultrastable and durable silicone coating on polycarbonate (PC) substrate through well-controlled nanoscale interfacial engineering. A nanopillar array is fabricated on the PC surface by vacuum-assisted hot embossing using anodic aluminum oxide (AAO) templates. Significant improvement in interfacial shear strength (ISS) is achieved for the silicone coating on the nanostructured PC surface. The delamination mechanism can be controlled by tuning the nanopillar size, and the maximum ISS of 9.9 MPa was reached on a surface with a nanopillar diameter of 320 nm. Attributed to the increased interfacial area and mechanical interlocking structure, the nanostructured interface can effectively dissipate interfacial stress and prevent cracking; therefore, maintaining excellent transparency and performance in the harsh environment. The coating exhibits extraordinary stability and durability when subjected to UV irradiation for 168 h, hydrothermal aging for 120 h, mechanical bending for 1000 cycles, and even surface damage. Thus, the tough silicone coating on polymer substrate realized by nanoscale interfacial engineering is a promising technique for highly stable and durable transparent surface protection.