Woven solutions for tissue engineering: Next-generation heart valves from fiber to function.

Study objective: Cardiovascular diseases remain one of the leading causes of morbidity and mortality worldwide, yet the availability of durable, patient-specific heart valve replacements is still limited. The aim is to utilize a biomimetic, textile-based design to mimic natural tissues, thereby creating customizable solutions with improved mechanical properties and scalable production for cardiovascular applications. Design: By leveraging advanced 3D weaving techniques, the feasibility of manufacturing anatomically adaptable and mechanically robust textile valves is demonstrated. CAD-based design workflows and functional materials such as shape memory Nitinol wires are part of this technology. The integration of form-defining geometries, multilayer structures and functional surface treatments is enabled through tailored binding design and machine adaptations. Main outcome and results: A textile-based heart valve implant was developed using advanced 3D weaving, CAD modelling and patient-specific imaging. Integrated leaflets and an annular ring were formed directly during weaving using mold inserts and multilayer structures, eliminating post-processing. Polyester and Nitinol materials provided mechanical stability and shape-memory functionality. Simulation models and SPH analysis validated pressure behaviour and deformation under physiological conditions. Functional zones with tailored stiffness, sealing and mobility were realized through binding variation and Jacquard control. A reproducible digital workflow, from CT segmentation to weaving on modified looms, enabled scalable production of anatomically accurate, functionally optimized heart valve prostheses. Mechanical evaluations reveal favourable performance in comparison to conventional valve designs. Conclusion: These findings highlight the potential of fiber and textile technology as a scalable, customizable clinically relevant platform for heart valve tissue engineering and future biomedical applications.