Recent developments in advanced manufacturing technologies for hernia repair meshes

Abstract

Hernias are one of the most common pathologies, with over 20 million surgeries performed annually worldwide. The most commonly used surgery to treat this pathology involves the implantation of fibrous mesh structures to reinforce weakened abdominal tissue. Although commercially available synthetic and biological meshes have significantly reduced recurrence rates, they are still associated with postoperative complications, such as chronic inflammation, foreign body response, and intra-abdominal adhesions. This review focuses on the use of advanced manufacturing techniques, specifically extrusion-based three-dimensional (3D) printing and electrospinning, in the development of next-generation mesh structures for hernia repair. These techniques offer precise control over structural architecture, customizable mechanical properties, and the ability to integrate bioactive compounds for patient-specific implant design. Furthermore, the combination of extrusion-based 3D printing and electrospinning presents a synergistic approach, utilizing 3D printing for robust mechanical support and electrospinning to mimic the native extracellular matrix (ECM) and regulate the biological interface, ultimately aiming to optimize tissue integration and minimize postoperative complications. In addition to the critical analysis of current advances, this review aims to serve as a practical guide for researchers in this field, providing a structured overview of the reported key parameters and conditions.