Key Design Considerations:

Physics
Fluid Dynamics: Blood flow through the heart is governed by principles of fluid dynamics. The valve must open and close effectively under varying pressure gradients, ensuring unidirectional flow and minimizing turbulence.
Pressure Gradients: The valve must withstand significant pressure differentials, especially during systole (when the heart contracts).

Chemistry
Material Selection: The materials must be biocompatible to prevent rejection and inflammation. Common materials include:
Biological materials (e.g., porcine or bovine tissue)
Synthetic materials (e.g., polymers like polyurethane or silicone, metals like titanium)

Biology
Hemodynamics: The valve design must ensure laminar blood flow to reduce shear stress on red blood cells.
Endothelialization: The valve should promote the growth of endothelial cells to minimize thrombogenicity (clot formation).

Design Concepts:
Physical design: The design will be inspired by natural valve mechanics. It will be a bi-leaflet design where two flexible leaflets open and close around a central orifice.
Polymer Selection
The choice of polymers is crucial for the success of the project. Potential polymer candidates include:
Polyurethanes: These polymers are known for their biocompatibility, mechanical properties, and ease of processing. They can be tailored to specific applications through chemical modifications.
Polyesters: Polyesters, such as polylactic acid (PLA) and polyglycolic acid (PGA), are biodegradable and biocompatible. They are often used in medical devices due to their ability to degrade over time.
Silicone: Silicone rubber is a highly biocompatible and durable material. It is often used in medical devices due to its flexibility and resistance to ageing.
Polyetheretherketone (PEEK): PEEK is a high-performance engineering plastic with excellent mechanical properties. It is biocompatible and has been used in various medical applications. However, due to its premium price, it may not be a cost-friendly choice for the project.

Valve Design:
The valve design should incorporate the following components:
Leaflets: The leaflets are the flexible structures that open and close to regulate blood flow. They can be designed using a variety of techniques, such as 3D printing or molding(preferred method).
Stent: The stent provides structural support for the valve and ensures proper positioning within the aorta. It can be made from a metal or polymer material.
Hinge: The hinge connects the leaflets to the stent and allows for proper opening and closing. It can be designed using a variety of techniques, such as laser cutting or machining.

Testing and Evaluation:
Once the valve is designed and manufactured, it must undergo rigorous testing to ensure its safety and efficacy. This will involve the use of:
Computational fluid dynamics (CFD) analysis: using computer simulations to evaluate the valve's hemodynamics performance and identify potential design flaws.

Conclusion: The cost-effective manufacturing of an artificial heart valve is a complex task that involves numerous challenges. By carefully considering design, selecting suitable materials, and conducting thorough testing, it is possible to manufacture a safe and effective valve that can enhance the lives of patients with heart valve disease.