Fused filament fabrication of patient-specific multifunctional implants for orthopedics

Polyetheretherketone (PEEK) is one of the most well-known high-performance polymers in the biomaterials industry for developing implants requiring high strength and durability. PEEK's impressive strength and durability, combined with its favorable biocompatibility and radiolucency, makes it a material of choice for orthopedic implants, including cranial implants, spinal fusion cages, and craniomaxillofacial implants. The conventional manufacturing route to develop such implants is primarily injection molding or machining. However, with the advent of high-temperature Fused Filament Fabrication (FFF) 3D printer setups, the manufacturing of PEEK-based biomedical implants is witnessing a seismic shift. The biomedical industry is taking advantage of high-temperature advanced FFF set-ups to 3D print PEEK-based implants with complex architecture and design rapidly and efficiently. This chapter provides a focused review of the state of the art of FFF-developed PEEK biomedical implants at research and commercial levels.