An Approach for 3D Microprinting Soft Robotic Surgical Tools at 1.5 French Length Scales for Endovascular Interventions

A wide range of endovascular interventions rely on surgical tools such as guidewire-catheter systems for navigating through blood vessels to, for example, deliver embolic materials, stents, and/or therapeutic agents to target sites as well as biopsy tools (e.g., forceps and punch needles) for medical diagnostics. In response to the difficulties in maneuvering such endovascular instruments safely and effectively to access intended sites in the body, researchers have developed an array of soft robotic surgical tools that harness fluidic (e.g., pneumatic or hydraulic) actuation schemes to support on-demand steering and control. Despite considerable progress, scaling these tools down to the sizes required for medical procedures such as cerebral aneurysm treatment and liver chemoembolization have been hindered by manufacturing-induced constraints. To provide a pathway to overcome these miniaturization challenges, this work presents a novel additive manufacturing strategy for 3D microprinting integrated soft actuators directly atop multilumen microfluidic tubing via “Two-Photon Direct Laser Writing (DLW)”. As an exemplar, a two-actuator tip was 3D printed onto custom dual-lumen tubing-resulting in a system akin to a 1.5 French (Fr) guidewire with a steerable tip. Experimental results revealed independent actuator control via the discretized lumens, with tip bending of approximately 60° under input pressures of 130 kPa via hydraulic actuation. These results suggest that the presented strategy could be extended to achieve new classes of fluidically actuated soft robotic surgical tools at unprecedented length scales for emerging applications in minimally invasive surgery.