We developed a new fabrication technique for 3-dimensional scaffolds for tissue engineering of human heart valve tissue. A human aortic homograft was scanned with an X-ray computer tomograph. The data derived from the X-ray computed tomogram were processed by a computer-aided design program to reconstruct a human heart valve 3-dimensionally. Based on this stereolithographic model, a silicone valve model resembling a human aortic valve was generated. By taking advantage of the thermoplastic properties of polyglycolic acid as scaffold material, we molded a 3-dimensional scaffold for tissue engineering of human heart valves. The valve scaffold showed a deviation of only 8 3–4% in height, length and inner diameter compared with the homograft. The newly developed technique allows fabricating custom-made, patient-specific polymeric cardiovascular scaffolds for tissue engineering without requiring any suture materials. Copyright © 2008 S. Karger AG, Basel Received: June 2, 2008 Accepted after revision: August 21, 2008 Published online: November 6, 2008 P.K. Schaefermeier Department of Cardiac Surgery, Laboratory for Tissue Engineering University Hospital of the Ludwig-Maximilians-University DE–81377 Munich (Germany) Tel. +49 89 7095 4791, Fax +49 89 7095 3465, E-Mail pschaefe@med.lmu.de © 2008 S. Karger AG, Basel 0014–312X/09/0421–0049$26.00/0 Accessible online at: www.karger.com/esr Schaefermeier /Szymanski /Weiss /Fu / Lueth /Schmitz /Meiser /Reichart /Sodian Eur Surg Res 2009;42:49–53 50 scaffolds resembling the anatomy of a native human heart valve [5] . Currently we describe a fabrication technique to generate a 3-dimensional heart valve scaffold, which was designed in the shape of the natural aortic valve, to provide temporary mechanical support for the construction of a viable and surgically feasible human heart valve. Material and Methods Prototyping Process An aortic homograft was used as a prototype to fabricate an individual heart valve scaffold with the correct anatomy of the human aortic valve. The homograft had not been accepted for heart surgery because of a positive microbiological test and was prepared for computed tomography (CT) scanning under the guideline of the laboratory for homografts at the German Heart Institute Berlin. We had previously introduced the idea of 3-dimensional reconstruction of heart valves. However, the prepared valve was scanned by CT at 2 mm slice distance and 0.1 ! 0.1 mm pixel size within all slices. The image data derived from CT were processed with our in-house software (Amira-Anaplast) which performs the image segmentation (border extraction with an appropriate density threshold). For specifying the region of valve location, the segmented images were further processed by a region-growing technique ( fig. 1 a, b). The 2-dimensional segmented images were interpolated from adjacent sections above and below to establish a visualized 3-dimensional aortic valve and root model. The 3-dimensional model was converted into a stereolithographic (STL) model and fed to the FDM 3000 stereolithography machine (Stratasys, Eden Prairie, Minn., USA) for construction of a resinic STL heart valve model. In addition, a negative cast of the ventricular side of the aortic homograft was created to construct a subsequent heart valve scaffold. Scaffold Material A polymeric material was used for the fabrication of a heart valve scaffold. Poly-4-hydroxybutyrate (P4HB; MW 700,000 by gel permeation chromatography, porosity 80%, pore size 80–240 m, thickness 300 m) is a biopolyester produced by a proprietary fermentation process (Tepha, Cambridge, Mass., USA). P4HB is a semicrystalline, thermoplastic elastomer with a melting point of approximately 60 ° C and a glass transition temperature of –51 ° C. Heart Valve Scaffold Fabrication The STL silicone model was then used to fabricate a polymeric heart valve. This consisted of 3 steps, as shown in figure 2 . Firstly, a rectangular piece of the polymer is wrapped around the negative cast of the silicone STL model (ventricular side of the STL silicone model) and trimmed off the potential sinus of Valsalva to shape a stent-like scaffold [4] . In the following step, another piece of polymer is wrapped around the stent-like polymeric scaffold and is fixed by a thermal processing technique. The upper edges of the polymer are trimmed according to the shape of the 3 leaflets, gently pressed onto the negative cast and manually molded. The third step is to use a polymer patch to form the sinus of Valsalva and the vascular wall of a valved conduit. The whole heart valve scaffold is then placed at 4–8 ° C for 24–48 h for cooling to develop the stable and exact shape of the aortic heart valve and root. Thus, in the whole process we accurately imitate the structure of the native aortic heart valve and use the thermoplastic technique to fabricate the trileaflet heart valve scaffold using a biodegradable porous polymer. Bioreactor Testing The P4HB heart valve scaffold for tissue engineering was tested in a bioreactor pulsed by a simple respirator (dual-phase control ventilator; Harvard Apparatus, Holliston, Mass., USA), with inspiration/expiration set to 30/70 and frequency to 50 strokes/ min. The testing device was completely transparent to facilitate observation of the function of the heart valve scaffold. The setup was connected to 2 sensor elements of a digital pressure monitoring device (Hellige Cardioserv, Freiburg, Germany), as described previously [5] .