Paul D Dalton

This study demonstrates a new approach to manufacturing biomimetic auricular surgical implants using melt electrowriting (MEW) technology to fabricate microfiber high‐density polyethylene (HDPE) scaffolds. An emerging filament‐driven printhead and MEW printer, termed the “MEWron”, is used to enable precise control over the material extrusion process and fiber formation. By predicting the optimal extrusion conditions, continuous and uninterrupted fiber production is achieved, enabling further optimization of filament‐driven MEW fibers with a diameter of 60.5 ± 2.6 µm. As a case study, an application of microfiber HDPE fabrication is selected that comprised the design and fabrication of personalized auricular (ear) surgical implants, specifically tailored to match the unique morphology of individual patients. Patient‐specific implant models matched to the natural shape and structure of the human ear are successfully fabricated. Furthermore, the manufactured implants exhibit excellent mechanical properties, offering a 13‐fold increase in tensile stiffness compared to MEW PCL scaffolds. Overall, this research demonstrates the feasibility and potential of MEW‐based HDPE implants as a promising alternative to traditional auricular reconstruction methods, offering an alternative avenue for improved patient outcomes and enhanced aesthetic results.