Mechanical Properties of 3D-Printed Porous Poly-ether-ether-ketone (PEEK) Orthopedic Scaffolds

Gummadi, Sudeep Kumar; Saini, Akshay; Owusu-Danquah, J.S.; Sikder, Prabaha

doi:10.1007/s11837-022-05361-6

Cited by 11 publications

(8 citation statements)

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“…The average pore sizes of the scaffolds are mentioned in the image headers. Similar to our previous efforts in developing scaffolds with highly consistent geometry and uniform-sized pores, FFF stands out to be a highly efficient yet sustainable manufacturing technique for developing scaffolds with controlled pore sizes and geometry [ 19 , 40 ]. Previous studies focused on developing porous BaTiO 3 -based piezoelectric scaffolds using conventional methods such as freeze casting [ 36 ] or particulate (salt)-leaching [ 28 ].…”

Section: Resultsmentioning

confidence: 84%

“…In FFF, the printed layers are glued to each other layer by layer to develop the final material; this process of product manufacturing can significantly influence the mechanical properties of the manufactured parts, especially when the print parameters and orientations are incorrect. Even though optimizing the 3D-printing parameters to achieve a robust 3D-printed part was not the scope of this study, our extensive experience in 3D printing of various polymers and composites [ 18 , 19 , 20 , 23 , 24 , 40 ] helped us achieve mechanically robust 3D-printed parts. To highlight, the 3D-printed PCL-25BT specimen’s mechanical properties were similar to the PCL-BT specimen (with 20 wt.% BaTiO 3 ) that was developed by conventional compression molding [ 39 ].…”

Section: Resultsmentioning

confidence: 99%

“…However, porous scaffolds can compromise the mechanical properties of load-bearing orthopedic scaffolds. In one of our recent studies, we observed that 3D-printed scaffolds with 300 µm pore size exhibit the highest yield compressive strength, and increasing the pore size beyond that would decrease the specimen’s yield strength [ 19 ]. The 320 µm pore-sized scaffolds in the present study resulted in the highest cell proliferation, indicating that such PCL-BT scaffolds would be beneficial for increasing cell growth kinetics and exhibit favorable mechanical properties.…”

Section: Resultsmentioning

confidence: 99%

“…On the contrary, “fused filament fabrication” (FFF) is a one-step, rapid and easy fabrication method to develop implants with favorable material properties. FFF can directly form robust scaffolds, which might not need sintering as an additional step [ 18 , 19 , 20 , 21 , 22 ]. Importantly, it involves much less material wastage than SLS or binder-jet printing.…”

Section: Introductionmentioning

confidence: 99%

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3D-Printed Piezoelectric Porous Bioactive Scaffolds and Clinical Ultrasonic Stimulation Can Help in Enhanced Bone Regeneration

2022

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This paper presents a comprehensive effort to develop and analyze first-of-its-kind design-specific and bioactive piezoelectric scaffolds for treating orthopedic defects. The study has three major highlights. First, this is one of the first studies that utilize extrusion-based 3D printing to develop design-specific macroporous piezoelectric scaffolds for treating bone defects. The scaffolds with controlled pore size and architecture were synthesized based on unique composite formulations containing polycaprolactone (PCL) and micron-sized barium titanate (BaTiO3) particles. Second, the bioactive PCL-BaTiO3 piezoelectric composite formulations were explicitly developed in the form of uniform diameter filaments, which served as feedstock material for the fused filament fabrication (FFF)-based 3D printing. A combined method comprising solvent casting and extrusion (melt-blending) was designed and deemed suitable to develop the high-quality PCL-BaTiO3 bioactive composite filaments for 3D printing. Third, clinical ultrasonic stimulation (US) was used to stimulate the piezoelectric effect, i.e., create stress on the PCL-BaTiO3 scaffolds to generate electrical fields. Subsequently, we analyzed the impact of scaffold-generated piezoelectric stimulation on MC3T3 pre-osteoblast behavior. Our results confirmed that FFF could form high-resolution, macroporous piezoelectric scaffolds, and the poled PCL-BaTiO3 composites resulted in the d33 coefficient in the range of 1.2–2.6 pC/N, which is proven suitable for osteogenesis. In vitro results revealed that the scaffolds with a mean pore size of 320 µm resulted in the highest pre-osteoblast growth kinetics. While 1 Hz US resulted in enhanced pre-osteoblast adhesion, proliferation, and spreading, 3 Hz US benefited osteoblast differentiation by upregulating important osteogenic markers. This study proves that 3D-printed bioactive piezoelectric scaffolds coupled with US are promising to expedite bone regeneration in orthopedic defects.

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Section: Resultsmentioning

confidence: 84%

Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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3D-Printed Piezoelectric Porous Bioactive Scaffolds and Clinical Ultrasonic Stimulation Can Help in Enhanced Bone Regeneration

2022

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“…Wang et al [34] employed tensile experiments to compare the tribological and mechanical properties of neat PEEK with short basalt fiber (BF) reinforced PEEK, finding that the ultimate tensile strength of BF PEEK (25 wt.% BF) is much higher than that of neat PEEK, reaching 150 MPa. Gummadi et al [35] applied an experimental and numerical investigation of PEEK scaffolds subjected to quasi-static compression tests. They observed that a PEEK scaffold with a 300 µm pore size performs the best compressive resistance ability, and the maximum stress is distributed along the longitudinal axis of the scaffold core under compressive load.…”

Section: Introductionmentioning

confidence: 99%

Numerical Study of Low-Velocity Impact Response of a Fiber Composite Honeycomb Sandwich Structure

Zhang

2023

Materials

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Engineering applications for honeycomb sandwich structures (HSS) are well recognized. Heterogeneous structures have been created using polyetheretherketone (PEEK) material, glass fiber-reinforced PEEK (GF-PEEK), and carbon fiber-reinforced PEEK (CF-PEEK) to further enhance the load-carrying capacity, stiffness, and impact resistance of HSS. In this study, we investigated the low-velocity impact response of HSS using numerical simulation. Our findings demonstrate that the choice of construction material significantly affects the impact resistance and structural stability of the HSS. We found that using fiber-reinforced PEEK significantly enhances the impact resistance of the overall structure, with GF-PEEK identified as the more appropriate face sheet material for the composite HSS based on a comparative study of load–displacement curves. Analysis of the plastic deformation of the honeycomb core, in combination with the stress and strain distribution of the composite HSS after low-velocity impact, indicates that CF-PEEK face sheets cause more noticeable damage to the core, resulting in evident plastic deformation. Additionally, we discovered that the use of fiber-reinforced materials effectively reduces deflection during low-velocity dynamic impact, particularly when both the face sheet and honeycomb core of the HSS are composed of the same fiber-reinforced PEEK material. These results provide valuable insights into the design and optimization of composite HSS for impact resistance applications.

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In-house processing of carbon fiber-reinforced polyetheretherketone (CFR-PEEK) 3D printable filaments and fused filament fabrication-3D printing of CFR-PEEK parts

Naganaboyina,

Nagaraju,

Sonaye

et al. 2023

Int J Adv Manuf Technol

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PEEK has several approving mechanical properties; however, for certain demanding applications such as automotive, PEEK does not exhibit the required strength. Moreover, if the PEEK parts are developed by Fused Filament Fabrication (FFF)-based 3D Printing, there is a high chance of having PEEK parts with decreased mechanical properties. Carbon Fiber (CF) reinforcement is a well-known method of mitigating the low mechanical properties of PEEK. Hence, in the present study, we attempted to develop CFreinforced PEEK (CFR-PEEK) parts via FFF. First, we developed homogeneous CFR-PEEK mixtures via ball milling and explored the effects of different milling duration and speeds on the extent of uniform dispersion of the CFs in the PEEK matrix. Next, we fed the CFR-PEEK milled powders into a hightemperature extrusion setup to develop uniform-diameter CFR-PEEK laments. We analyzed the effects of different extrusion parameters on the uniform-diameter CFR-PEEK lament quality to make it suitable for 3D Printing. Finally, the CFR-PEEK laments were used in a high-temperature FFF setup to develop designspeci c parts. Our results indicate that 400 rpm and 4h were apt for developing uniform CFR-PEEK mixtures. Interestingly, increasing the CF content above 10 vol% resulted in brittle laments. The extrusion temperature, speed, and cooling rate played a major role in forming the uniform-diameter CFR-PEEK laments. Finally, the 3D printed CFR-PEEK parts exhibited a tensile strength of 49MPa, lesser than un lled PEEK. We indicate that poor interfacial bonding of the CF with the PEEK matrix is a primary reason for this reduced strength. In addition, printing defects such as pores also contributed to the reduced strength of the CFR-PEEK parts.

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Mechanical Properties of 3D-Printed Porous Poly-ether-ether-ketone (PEEK) Orthopedic Scaffolds

Cited by 11 publications

References 50 publications

3D-Printed Piezoelectric Porous Bioactive Scaffolds and Clinical Ultrasonic Stimulation Can Help in Enhanced Bone Regeneration

3D-Printed Piezoelectric Porous Bioactive Scaffolds and Clinical Ultrasonic Stimulation Can Help in Enhanced Bone Regeneration

Numerical Study of Low-Velocity Impact Response of a Fiber Composite Honeycomb Sandwich Structure

In-house processing of carbon fiber-reinforced polyetheretherketone (CFR-PEEK) 3D printable filaments and fused filament fabrication-3D printing of CFR-PEEK parts

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