3D rotary tunnel braiding system with active control: algorithm and structure formation for complex braided designs

Cardiovascular stents are often produced using a technique called maypole braiding. Maypole braiding is a highly productive manufacturing method in comparison to laser cutting but not versatile as laser cutting. Due to design and machine-specific limitations, these braiding machines are not suitable for versatile stent production and patient specific requirements, insofar a new flexible 3D rotatory tunnel braiding machine is developed. The novel machine is therefore including new operation principles to control carrier transfers, as well as an electronic fibre tension control system. Different aspects of the machine development such as structure possibilities, constructive requirements and consequences were observed. Various algorithms have been developed to enable collision-free carrier tracks during the automated set-up of the machine and in production. Furthermore, a variety of other structure formation options can be realised, such as flat braiding with identical horn gears rotating at different speeds. Utilising the new machine manufactures are enabled to produce versatile and patient specific cardio vascular implants in a highly productive way.