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<p>Fused Fillament Fabrication (FFF) is increasingly used to fabricate patient-specific medical devices and implants. However, processing polyetheretherketone (PEEK) for biomedical applications is challenging due to its high melting point (above 340&#xa0;°C) and bioinert nature, which limits bone tissue integration. To address this, PEEK-based filaments with 20 wt% bioglass (BG) or hydroxyapatite (HA) were developed via extrusion and optimized for FFF 3D printing. The filaments and 3D-printed samples were analyzed for thermal, morphological, and mechanical properties. Scanning electron microscopy revealed uniform dispersion of BG and HA particles in the PEEK matrix. The addition of these inorganic phases increased crystallinity, particularly with BG, while maintaining stable crystallization and melting temperatures, ensuring compatibility with FFF. Mechanical tests showed significant improvements in tensile and flexural properties, with BG-reinforced composites outperforming HA-reinforced ones due to higher crystallinity. Optimized FFF parameters enabled successful 3D printing of PEEK composites. The 3D-printed samples exhibited strong interlayer adhesion and enhanced mechanical properties compared to pure PEEK. PEEK/HA showed moderate improvements, with a 5.6% increase in bending resistance (83.22&#xa0;MPa), a 7.8% rise in tensile strength (71.9&#xa0;MPa), and a 15.4% boost in Young’s modulus (3.737 GPa). In contrast, PEEK/BG demonstrated superior performance, with a 57.4% increase in bending resistance (124.05&#xa0;MPa), a 42.9% rise in tensile strength (95.2&#xa0;MPa), and an 85.1% improvement in bending modulus (4.61 GPa), making it ideal for load-bearing applications. The study validated the potential of PEEK/HA and PEEK/BG composites for biomedical use, particularly in orthopedic and dental implants, with BG-enhanced PEEK showing exceptional mechanical performance.</p> Graphical abstract <p></p>

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A novel poly(etheretherketone)-bioactive glass composite filament for 3D-printed bone repair: development, mechanical performance, and comparison with PEEK/HA

  • 期刊论文

  • 发表日期：

    2025年7月31日

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  • Mohamed Timoumi,
  • Najoua Barhoumi,
  • Amna Znaidi,
  • Abderrahim Maazouz,
  • Khalid Lamnawar

摘要

Fused Fillament Fabrication (FFF) is increasingly used to fabricate patient-specific medical devices and implants. However, processing polyetheretherketone (PEEK) for biomedical applications is challenging due to its high melting point (above 340 °C) and bioinert nature, which limits bone tissue integration. To address this, PEEK-based filaments with 20 wt% bioglass (BG) or hydroxyapatite (HA) were developed via extrusion and optimized for FFF 3D printing. The filaments and 3D-printed samples were analyzed for thermal, morphological, and mechanical properties. Scanning electron microscopy revealed uniform dispersion of BG and HA particles in the PEEK matrix. The addition of these inorganic phases increased crystallinity, particularly with BG, while maintaining stable crystallization and melting temperatures, ensuring compatibility with FFF. Mechanical tests showed significant improvements in tensile and flexural properties, with BG-reinforced composites outperforming HA-reinforced ones due to higher crystallinity. Optimized FFF parameters enabled successful 3D printing of PEEK composites. The 3D-printed samples exhibited strong interlayer adhesion and enhanced mechanical properties compared to pure PEEK. PEEK/HA showed moderate improvements, with a 5.6% increase in bending resistance (83.22 MPa), a 7.8% rise in tensile strength (71.9 MPa), and a 15.4% boost in Young’s modulus (3.737 GPa). In contrast, PEEK/BG demonstrated superior performance, with a 57.4% increase in bending resistance (124.05 MPa), a 42.9% rise in tensile strength (95.2 MPa), and an 85.1% improvement in bending modulus (4.61 GPa), making it ideal for load-bearing applications. The study validated the potential of PEEK/HA and PEEK/BG composites for biomedical use, particularly in orthopedic and dental implants, with BG-enhanced PEEK showing exceptional mechanical performance.

Graphical abstract