Advanced 3D Printing of Polyetherketoneketone Hydroxyapatite Composites via Fused Filament Fabrication with Increased Interlayer Connection

Krzysztof Rodzeń, Eiméar O’Donnell, Frances Hasson, Alistair McIlhagger, Brian J. Meenan, Jawad Ullah, Beata Strachota, Adam Strachota, Sean Duffy, Adrian Boyd

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Abstract

Additively manufactured implants, surgical guides, and medical devices that would have direct contact with the human body require predictable behaviour when stress is applied during their standard operation. Products built with Fused Filament Fabrication (FFF) possess orthotropic characteristics, thus, it is necessary to determine the properties that can be achieved in the XY- and Z-directions of printing. A concentration of 10 wt% of hydroxyapatite (HA) in polyetherketoneketone (PEKK) matrix was selected as the most promising biomaterial supporting cell attachment for medical applications and was characterized with an Ultimate Tensile Strength (UTS) of 78.3 MPa and 43.9 MPa in the XY- and Z-directions of 3D printing, respectively. The effect of the filler on the crystallization kinetics, which is a key parameter for the selection of semicrystalline materials suitable for 3D printing, was explained. This work clearly shows that only in situ crystallization provides the ability to build parts with a more thermodynamically stable primary form of crystallites.
Original languageEnglish
Article number3161
Pages (from-to)1-15
Number of pages15
JournalMaterials
Volume17
Issue number13
Early online date27 Jun 2024
DOIs
Publication statusPublished online - 27 Jun 2024

Data Access Statement

The original contributions presented in the study are included in the
article/Supplementary Materials, further inquiries can be directed to the corresponding authors.

Keywords

  • additive manufacturing
  • crystallization kinetics
  • advanced semicrystalline polymers
  • 3D printing
  • polyetherketoneketone
  • hydroxyapatite

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