Journal article
Investigating the Feasibility and Performance of Hybrid Overmolded UHMWPE 3D-Printed PEEK Structural Composites for Orthopedic Implant Applications: A Pilot Study
Bioengineering (Basel), v 11(6), 616
17 Jun 2024
Featured in Collection : UN Sustainable Development Goals @ Drexel
Abstract
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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Details
- Title
- Investigating the Feasibility and Performance of Hybrid Overmolded UHMWPE 3D-Printed PEEK Structural Composites for Orthopedic Implant Applications: A Pilot Study
- Creators
- James A. Smith - Drexel UniversityCemile Basgul - Drexel UniversityBita Soltan Mohammadlou - Drexel UniversityMark AllenSteven M. Kurtz - Drexel University
- Publication Details
- Bioengineering (Basel), v 11(6), 616
- Publisher
- MDPI
- Resource Type
- Journal article
- Language
- English
- Academic Unit
- School of Biomedical Engineering, Science, and Health Systems; Mechanical Engineering and Mechanics; A.J. Drexel Nanomaterials Institute
- Web of Science ID
- WOS:001254637700001
- Scopus ID
- 2-s2.0-85197953142
- Other Identifier
- 991021889514904721
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- Collaboration types
- International collaboration
- Web of Science research areas
- Biotechnology & Applied Microbiology
- Engineering, Biomedical