Development of CF-PEKK Composite Bone Plates via 3D Printing and Pressing
Tuesday, September 3, 2024
3:00 PM-5:00 PM
BIOMED Master's Thesis Defense
Title:
Development of CF-PEKK Composite Bone Plates via 3D Printing and Pressing for Void Reduction and Improved Mechanical Strength
Speaker:
Pratik Chapagain, Master's Candidate
School of Biomedical Engineering, Science and Health Systems
Drexel University
Advisor:
Steven M. Kurtz, PhD
Research Professor
School of Biomedical Engineering, Science and Health Systems
Drexel University
Details:
The search for innovative implant materials in orthopedics has led to the exploration of advanced thermoplastics in the family of PAEK, a high performance thermoplastic. These materials have potential to overcome the drawbacks of traditional metal implants like stress shielding and corrosion. This thesis, “Development of PEKK and CF-PEKK Composite Bone Plates via 3D Printing and Pressing for Void Reduction and Improved Mechanical Strength," addresses these challenges by examining the effectiveness of Polyetherketoneketone (PEKK) composite in orthopedic applications. PEKK has only caught attention in orthopedic applications in the recent years. Unlike metals, the modulus of these composites are comparable to that of bone. This research focuses on developing and optimizing trauma plates made from PEKK and carbon fiber reinforced PEKK (CF-PEKK) using a 2-step process; fabrication through 3D printing followed by pressing, a post processing step that can improve the mechanical strength and structural integrity of bone plates by reducing voids and enhancing material consolidation.
The goals of this research were achieved by printing PEKK and CF-PEKK plates, custom designing and machining a mold for pressing, optimizing consolidation parameters like temperature and pressure, and conducting mechanical testing and Scanning Electron Microscopy (SEM) and to check for improvements post pressing. Resulting plates showed significant improvements in the mechanical performance of pressed plates with flexural strength and modulus significantly increasing (p<0.0001) after pressing. SEM confirmed a notable reduction in voids and improved surface quality indicating good consolidation.
This research makes valuable contribution in implant design in orthopedics. It demonstrates that PEKK & its composite bone plates show superior mechanical properties that closely align with the requirements for bone plate implants. This sets a strong foundation for potential clinical use of PEKK and its composite to address the challenges with metal implants. This thesis advances the understanding of high-performance polymer composite in biomedical engineering providing an innovative approach to manufacture orthopedic implants.
Contact Information
Natalia Broz
njb33@drexel.edu