Process-Driven Optimization of FDM Porous PEEK Scaffolds for Alloplastic Bone Grafts

Area of Science:

• Biomaterials Science
• Additive Manufacturing
• Regenerative Medicine

Background:

• Polyether ether ketone (PEEK) is a high-performance biomaterial with excellent mechanical properties, chemical stability, and biocompatibility, making it suitable for orthopedic and craniofacial applications.
• Additive manufacturing (AM) of PEEK, especially via fused deposition modeling (FDM), presents challenges due to its high melting point and narrow processing window, hindering scaffold fabrication.
• Existing computer-aided design (CAD) based lattice designs for PEEK scaffolds often fail during FDM processing, leading to structural inconsistencies and poor fidelity.

Purpose of the Study:

• To develop a novel and practical strategy for producing porous PEEK scaffolds with optimized architecture for bone graft applications using AM.
• To overcome the limitations of CAD-based designs in FDM processing of PEEK.
• To demonstrate the efficacy of a process-driven approach by adjusting slicing parameters for reproducible scaffold fabrication.

Main Methods:

• A process-driven approach was adopted, focusing on the iterative adjustment of slicing parameters within the FDM process.
• Initial CAD-based lattice designs were modified and optimized through parameter tuning to achieve successful printing.
• The optimized scaffolds were characterized for morphology, mechanical integrity, geometric fidelity, and pore characteristics.

Main Results:

• A reproducible method for producing porous PEEK scaffolds was successfully developed by manipulating slicing parameters.
• The fabricated scaffolds exhibited interconnected porosity with pore dimensions ranging from 100 to 400 μm, suitable for supporting osteoblast functions and vascularization.
• The optimized scaffolds demonstrated consistent morphology, mechanical integrity, and geometric fidelity, validating the process-driven approach.

Conclusions:

• Manipulating slicing software parameters is crucial for overcoming CAD limitations and successfully 3D printing high-performance thermoplastics like PEEK.
• This work establishes a scalable pathway for creating customized, load-sharing PEEK scaffolds for bone tissue engineering.
• The findings highlight the potential of integrating advanced manufacturing strategies with optimized material processing for regenerative medicine applications.