Astronaut holding a toner cartridge; Copyright: Auxilium/NASA

Implants: Successful 3D bioprinting in space

How weightlessness could bring better healing down to Earth

It sounds like science fiction, but it became realityfor the first time on the International Space Station ISS: bioprinted nerve implants - also for better healing on Earth.

We spoke to Dr. Jacob Koffler, CEO of Auxilium Biotechnologies and Assistant Professor of Neuroscience and Bioengineering. He led the development of the AMP-1 bioprinter and supported the planning and implementation for the ISS mission in November 2023. He tells us about the project, the findings and, above all, the benefits of the physics of zero gravity.

Topics in the article:

Goal: Repairing nerves
Printing in zero gravity
Efficient use of the printer
Commercial printing in space
Approval of implants on Earth
Practical reasons for printing in space

The origin of the project: repairing nerves with medical implants

Auxilium Biotechnologies, based in San Diego, California, specializes in regenerating peripheral nerves after injury. The company develops implants that act as "bridges" between nerve endings to enable healing.

The implants are produced in different sizes, depending on the type of injury. They are manufactured using 3D printing technology, among other things. Special nanoparticles are integrated into the current third generation of implants, which are designed to significantly improve regeneration. The following animation shows how they work:

Why does it make sense printing the implants in space?

Dr. Koffler describes: "One problem with production on Earth was that these particles sink due to gravity and are unevenly distributed. We were interested in whether this could be changed in zero gravity." NASA supported the project as they believe it can offer clear benefits for patients on Earth. The assistant professor explains the added value for the medical implants:

This is what the printed "nerve bridge implants" look like. The material: biological, proprietary ink with nanoparticles to promote nerve regeneration:

Eight printed implants; copyright: Auxilium Biotechnologies

This is how the nanoparticles are distributed in the material

Graphic showing how nanoparticles sink to earth and are evenly distributed in the material in space.

Time is money: Efficient use and control of the printer

It was very important to keep the time and effort for the astronauts as low as possible. After all, their working time is precious. Auxilium was able to control the printing from Earth with the exception of a few simple steps. NASA astronaut Barry "Butch" Wilmore only had to take the cartridge with the ink from the fridge and insert it into the bioprinter.

Astronaut holding printer toner on the ISS; copyright: Auxilium/NASA

Will commercial production be possible?

For over a year, the AMP-1 bioprinter underwent special modifications for use on the space station. "All parts have to be firmly secured because they could injure the space travelers. The device also had to function as autonomously as possible," Koffler continues.

The plan for the ISS mission worked. The frequency and the large output alone represent a success and pave the way for the next level: the transition from conducting pure research to the potential commercial mass production of medical products in space.

Auxilium plans to use the system on various platforms, not just on space stations such as the ISS. Future commercial space stations and autonomous "free-flying platforms" are also possible. After all, a few hours in zero gravity are enough for printing:

A "free-flying platform" is an autonomous platform or module that moves independently of a space station or a carrier system in space and performs specific tasks there. It is, so to speak, a "flying laboratory or working satellite".

There is still a lot of work to be done before the implants are approved on Earth

Making the printer functional for use on the space station was one challenge - obtaining approval for the printed implants is an even greater one.

The implants are currently undergoing preclinical animal testing. However, comprehensive tests are required for approval by the US Food and Drug Administration (FDA). Biocompatibility and toxicity must be proven. Manufacturing in space is considered a non-sterile environment and is a special case that has not yet been defined in regulatory terms. And: the FDA has no previous experience with space-based bioprinting processes. Step by step, however, progress is being made.

Additional experiment

These artificial perfusable blood vessels were also printed. Looks like a work of art, doesn't it?

gedruckte Blutgefäße - die aussehen wie ein Baum; copyright: Auxilium Biotechnologies

Many innovations originally developed for space medicine are now benefiting people on Earth.

Click here to learn more: High-tech from space for everyone

Practical reasons for 3D printing in space

NASA sees great potential in the technology both for medical care in space and for applications on Earth. Locally manufactured medical equipment could be vital, especially for long-term missions.

Auxilium is pursuing a unique concept: they are using the advantages of microgravity not because 3D printing does not work on Earth - it does - but because the quality of the implants can be significantly improved through evenly distributed nanoparticles and potentially new biological effects. The aim is to make medical innovations from space accessible for use on Earth.

The innovations tested and developed in space could accelerate regenerative medicine on Earth and lead to customized treatments for patients with nerve damage. And beyond this they could improve techniques for bioprinting other tissues or even organs in the future.

Smiling woman with brown hair - Natascha Mörs; Copyright: beta-web

Author: Natascha Mörs | Editorial team COMPAMED-tradefair.com

Multimedia editor Natascha Mörs has been writing and filming for COMPAMED.de for almost 20 years. She enjoys providing insights into the details of materials, miniaturized components and talking to suppliers of all the components that make medical technology possible.