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Abstract Owing to its superior bulk mechanical properties, poly (ether ether ketone) (PEEK) has gained popularity over the past 15 years as a metal substitute in biomedical implants. Low surface energy is a fundamental issue with PEEK implants. This low surface energy caused by a moderately hydrophobic surface may be able to inhibit cellular adherence and result in the development of an inflammatory response, which may result in cell necrosis and apoptosis. In this work, plasma and ozone treatments have been utilized to surface activate PEEK and graft ionic bioactive polymer polyNaSS (poly (sodium styrene sulfonate)) successfully on the surface to promote cellular attachment and biomineralization. The main goal of our research has been to find a stable green process for surface modification of PEEK by plasma/ozone approaches to increase PolyNaSS grafting efficiency and biomineralization. To further the field of bioactive orthopedic and dental implant technology, this research attempts to address a significant constraint of PEEK implants while preserving their favorable mechanical properties.
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Investigating the Feasibility and Performance of Hybrid Overmolded UHMWPE 3D-Printed PEEK Structural Composites for Orthopedic Implant Applications: A Pilot Study
Ultra-high-molecular-weight polyethylene (UHMWPE) components for orthopedic implants have historically been integrated into metal backings by direct-compression molding (DCM). However, metal backings are costly, stiffer than cortical bone, and may be associated with medical imaging distortion and metal release. Hybrid-manufactured DCM UHMWPE overmolded additively manufactured polyetheretherketone (PEEK) structural components could offer an alternative solution, but are yet to be explored. In this study, five different porous topologies (grid, triangular, honeycomb, octahedral, and gyroid) and three surface feature sizes (low, medium, and high) were implemented into the top surface of digital cylindrical specimens prior to being 3D printed in PEEK and then overmolded with UHMWPE. Separation forces were recorded as 1.97–3.86 kN, therefore matching and bettering the historical industry values (2–3 kN) recorded for DCM UHMWPE metal components. Infill topology affected failure mechanism (Type 1 or 2) and obtained separation forces, with shapes having greater sidewall numbers (honeycomb-60%) and interconnectivity (gyroid-30%) through their builds, tolerating higher transmitted forces. Surface feature size also had an impact on applied load, whereby those with low infill-%s generally recorded lower levels of performance vs. medium and high infill strategies. These preliminary findings suggest that hybrid-manufactured structural composites could replace metal backings and produce orthopedic implants with high-performing polymer–polymer interfaces.
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- Award ID(s):
- 2216175
- PAR ID:
- 10539391
- Publisher / Repository:
- MDPI
- Date Published:
- Journal Name:
- Bioengineering
- Volume:
- 11
- Issue:
- 6
- ISSN:
- 2306-5354
- Page Range / eLocation ID:
- 616
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.3390/bioengineering11060616
