Related Experiment Video
Updated: May 3, 2026
05:32
A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars
Published on: August 4, 2018
14.5K
Additively Manufactured Partially Porous PAEK Topologies for Proximal Tibia Revision Cones and Sleeves.
Paul M DeSantis1, Emma Barnes2, Abigail Tetteh2
1Implant Research Core, School of Biomedical Engineering, Science and Health Systems, Drexel University, Philadelphia, PA, 19104, USA. pmd67@drexel.edu.
Annals of Biomedical Engineering
|February 19, 2026
Summary
Researchers developed 3D-printed polyaryletherketone (PAEK) metaphyseal cones and sleeves for knee replacements. These non-metal implants offer a strong, porous alternative for bone ingrowth, addressing metal sensitivities and improving revision arthroplasty stability.
Area of Science:
- Biomaterials Engineering
- Orthopedic Surgery
- Additive Manufacturing
Background:
- Metaphyseal cones and sleeves are crucial for revision total knee arthroplasty stability.
- Metal hypersensitivity and osteolysis necessitate alternatives to traditional metal implants.
- Polyaryletherketone (PAEK) offers a non-metal option with potential for bone integration.
Purpose of the Study:
- To investigate the feasibility of additively manufacturing highly porous PAEK metaphyseal components.
- To determine if these components can withstand knee mechanical forces while allowing bone ingrowth.
- To optimize PAEK printing parameters for strength and porosity.
Main Methods:
- Taguchi optimization was employed to identify optimal parameters and porous geometries for 45° shear-compression strength.
- Micro-computed tomography (Micro-CT) assessed the quality of printed porosity.
- Mechanical testing evaluated ultimate load capacity under simulated worst-case scenarios.
Main Results:
- Low-melt (LM) PAEK samples demonstrated superior mean performance compared to standard polyetheretherketone (PEEK) samples.
- Component geometry and percent porosity were key factors for LM PAEK strength.
- All tested PAEK samples exceeded the required 5.5 kN ultimate load, proving their mechanical robustness.
- Porosity errors were statistically similar between PEEK and LM PAEK groups.
Conclusions:
- Additive manufacturing can produce highly porous, non-metal PAEK metaphyseal components for revision knee arthroplasty.
- These 3D-printed PAEK implants demonstrate sufficient strength for knee joint loading.
- This study provides a proof-of-concept for advanced, non-metal implant solutions addressing limitations of current metal devices.
