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Thesis
Development of PEKK and CF-PEKK Composite Bone Plates via 3D Printing and Pressing for Void Reduction and Improved Mechanical Strength
Master of Science (M.S.), Drexel University
Sep 2024
DOI:
https://doi.org/10.17918/00010780
Abstract
The search for innovative implant materials for orthopedics application has led to the exploration of advanced, high performing thermoplastics in the PAEK family. These materials have potential to overcome the drawbacks of traditional metal implants like stress shielding and corrosion. This thesis, "Development of PEKK and CF-PEKK Composite Bone Plates via 3D Printing and Pressing for Void Reduction and Improved Mechanical Strength," addresses these challenges by examining the effectiveness of Polyetherketoneketone (PEKK) composite for such orthopedic applications. PEKK has only caught attention in orthopedic applications in recent years. Unlike metals, the modulus of these composites is comparable to that of bone. This research focuses on developing and optimizing trauma plates made from PEKK and carbon fiber reinforced PEKK (CF-PEKK) using a 2-step process; fabrication through 3D printing followed by pressing, a post processing step that can improve the mechanical strength and structural integrity of bone plates by reducing voids and enhancing material consolidation. The goals of this research were achieved by printing PEKK and CF-PEKK plates, custom designing and machining a mold for pressing, optimizing consolidation parameters like temperature and pressure, and conducting mechanical testing and Scanning Electron Microscopy (SEM) and to check for improvements post pressing. Resulting plates showed significant improvements in the mechanical performance of pressed plates with flexural strength (Unpressed PEKK: 51.33 ± 1.01 MPa vs Optimal Pressed PEKK: 121.41 ± 10.49 MPa, Unpressed CF-PEKK: 32.29 ± 1.29 MPa vs Optimal Pressed CF-PEKK: 241.73 ± 14.9 MPa) and modulus (Unpressed PEKK: 2.41 ± 0.09 GPa vs Optimal Pressed PEKK: 5.06 ± 0.72 GPa, Unpressed CF-PEKK: 1.67 ± 0.04 GPa vs Optimal Pressed CF-PEKK: 8.33 ± 0.90 GPa) significantly increasing (p<0.0001) after pressing. SEM confirmed a notable reduction in voids and improved surface quality indicating good consolidation. This research makes valuable contribution in implant design in orthopedics. It demonstrates that PEKK & its composite bone plates show superior mechanical properties that closely align with the requirements for bone plate implants. This sets a strong foundation for potential clinical use of PEKK and its composite to address the challenges with metal implants. This thesis advances the understanding of high-performance polymer composite in biomedical engineering providing an innovative approach to manufacture orthopedic implants.
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Details
- Title
- Development of PEKK and CF-PEKK Composite Bone Plates via 3D Printing and Pressing for Void Reduction and Improved Mechanical Strength
- Creators
- Pratik Chapagain
- Contributors
- Steven M. Kurtz (Advisor)
- Awarding Institution
- Drexel University
- Degree Awarded
- Master of Science (M.S.)
- Publisher
- Drexel University; Philadelphia, Pennsylvania
- Number of pages
- xi, 70 pages
- Resource Type
- Thesis
- Language
- English
- Academic Unit
- School of Biomedical Engineering, Science, and Health Systems (1997-2026); Drexel University
- Other Identifier
- 991021930814104721