From PTFE Latex to Three Dimensional‐Printed Vascular Grafts Fabricated by DLP 3D Printing

Vascular endoprostheses, composed of a metallic stent covered with an impermeable graft, are the gold standard for treating aortic aneurysms by isolating the weakened vessel from blood flow, preventing rupture. Expanded PTFE (ePTFE), the most common graft material, is traditionally produced by paste extrusion and stretching, which is energy‐intensive, requires lubricants, and cannot reproduce the aorta's complex morphology. Here, the fabrication of PTFE grafts by 3D printing PTFE latex particles using digital light processing (DLP) is reported. This strategy allows rapid manufacturing of devices with morphologies adapted to patient anatomy. PTFE nanoparticles are embedded in a photocrosslinked dimethacrylated pluronic resin, enabling direct printing in water. Optimized thermal and chemical postprinting treatments transform the composite into a fully formed PTFE device. This two‐step process yields materials with distinct mechanical, structural, and biocompatible features. Printed PTFE exhibits flexibility (Young's modulus: 17.8 ± 7 MPa) and high strength (elongation at break 157 ± 98%), while maintaining impermeability (withstanding up to 4 bar) due to an internal generated porosity (27.2 ± 8%). Fibroblast cytotoxicity tests (ISO 10993) confirm biocompatibility. This innovative approach, based on printing of PTFE latex particles via DLP, offers a promising route toward the fast fabrication of patient‐specific PTFE vascular grafts.