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Updated: Jun 25, 2026
3D Planning and Printing of Patient Specific Implants for Reconstruction of Bony Defects
Published on: August 4, 2020
Application-matched point-of-care 3D printing of functionalized polyetheretherketone (PEEK) composites for
Jokin Zubizarreta Oteiza1,2, Yannick Krieger3, Daniel Seiler4
1Medical Additive Manufacturing Research Group (Swiss MAM), Department of Biomedical Engineering, University of Basel, Hegenheimermattweg 167b, Allschwil, 4123, Switzerland.
Background:
Native polyetheretherketone (PEEK) exhibits limitations in mechanical strength, radiographic visibility, and bioactivity for craniomaxillofacial (CMF) applications. This proof-of-concept study establishes the feasibility of point-of-care (POC) manufacturing for three functionalized PEEK composites for patient-specific CMF implants using a high-temperature material extrusion (MEX) system, with application-specific material selection to overcome these limitations.
Methods:
Carbon fiber-reinforced PEEK (CFR-PEEK), barium sulfate-filled PEEK (BaSO₄-PEEK), and biphasic calcium phosphate-filled PEEK (BCP-PEEK) were fabricated into patient-specific mandibular reconstruction plates, orbital floor implants, and chin augmentation implants, respectively. Manufacturing success rates, dimensional accuracy via root mean square (RMS) deviation analysis, post-sterilization dimensional stability, and layer adhesion quality were evaluated.
Results:
Fabrication success rates of 100% (CFR-PEEK), 100% (BaSO₄-PEEK), and 85.7% (BCP-PEEK) were achieved. Dimensional accuracy analysis revealed RMS deviations of 0.16-0.29 mm between 3D-printed implants and original designs, within clinically acceptable ranges. Post-sterilization dimensional changes were minimal (RMS 0.05-0.07 mm). Complete layer adhesion was demonstrated across all materials, with no delamination or cracking observed.
Conclusion:
These findings establish the manufacturing viability of POC fabrication of application-matched PEEK composites for patient-specific CMF implants, enhancing mechanical, radiographic, and bioactive properties whilst maintaining geometric customization.
