Scientists are developing a vegan 3D-printed nose from ‘artificial’ cartilage made from crushed softwood

A ‘3D printed vegan nose’ – made from shredded softwood and a key ingredient in face cream – is being developed by British scientists for people who have lost their own noses to accidents or cancer.

Right now, surgeons must dissect victims’ ribs for cartilage, which they will use to create the superstructure of the patient’s new nose.

This can often involve multiple surgeries removing up to three lower ribs.

Their removal can lead to long-term health problems, while the cartilage that is preserved is not ideal, being less flexible and more brittle than the one that makes up the nose.

As a result, experts at Swansea University have created an “artificial” cartilage that can be 3D printed to create the exact shape needed for the recipient’s face.

It’s made of “nanocellulose hydrogel” and “hyaluronic acid,” said would-be surgeon Thomas Jovic, who dreamed up the concoction.

While this may sound scary, Dr. Jovic that both are naturally derived products.

He explained: “Nanocellulose hydrogel is basically shredded softwood. And hyaluronic acid, found in many skin creams and face fillers, is produced by bacteria. Both are vegan.”

A biological catalyst is added to the mixture so that after 3D printing it “cures” similar to epoxy resin.

Mr Jovic said: “The result is a material that is around 10 times more flexible than natural nasal cartilage.”

But that is not the end product. Autologous cartilage cells are then removed from the patient, multiplied in the laboratory and placed in a solution.

The artificial cartilage – which is actually just a “framework” – is then dipped into this cell solution. These colonize the structure over time and stiffen it before it is surgically implanted. The technique can also be used to rebuild damaged ears.

dr Jovic and colleague Professor Iain Whitaker, Chair of Plastic Surgery at Swansea University Medical School, have presented their work to the British Association of Plastic, Reconstructive and Aesthetic Surgeons (BAPRAS), which supports them. So are the Royal College of Surgeons and the Scar Free Foundation, a charity.

Prof Whitaker said: “Generally, when we want to reconstruct cartilage in the face, we face a lengthy and complex operation that can be fraught with challenges.

“The exciting part of this research is that we are taking 3D printing technology and combining it with tissue engineering to create a biological tissue.

“This process increases personalization and creates a permanent solution via a process that is much less complex than traditional methods, reducing uptime and eliminating the need to manually carve the nose structure.

“This material can form a perfect replica that comes from plants and is structurally robust.”

The next steps are to verify that the material does not elicit an immune response and to start animal testing.

Prof. Whitaker said: “The clinical translation of this work will revolutionize plastic surgery.”