Medical PEEK 3D Printed Prosthesis
PEEK 3D printing prosthesis is the latest generation of implanted prosthesis materials. In cranial repair surgery, many patients choose PEEK materials with good results.
Medical PEEK 3D Printed Prostheses: New Medical Options
PEEK 3D printed prostheses are the latest generation of implantable prosthetic materials for implants. In the development of prosthesis implantation, stainless steel was used in the early days, but it had problems such as composition, fatigue resistance and elastic modulus, and was gradually replaced by titanium alloy. Titanium alloy has good biocompatibility and good combination with bone tissue, and is widely used at present. With the development of 3D printing technology, PEEK materials are increasingly used in the medical field.
The use of PEEK custom implants in the craniomaxillofacial region was first reported in the literature in 2007 and can be used to 3D print custom implants to meet the clinical needs of personalized complex prostheses. For example, 3D printed PEEK prostheses involving orbits, cheekbones, maxilla. PEEK materials are commonly used in orthopedics, maxillofacial surgery, and plastic and cosmetic surgery for bony defect repair and bony filling. It has the characteristics of light weight, good strength, stable structure, not easy to deform, good biocompatibility and low rejection rate. Generally, CT scans are used to scan the facial structure data of the patient, and the shape, area, and thickness of the desired implant are comprehensively calculated, and finally molded by printing technology.
PEEK implants can be applied to the forehead, brow arch, cheekbones, tear trough, nasal base, chin, jawline, etc. The prosthesis made from individual CT data has a high degree of anastomosis, is firm and not easy to displace, and has low foreign body sensation. In the field of plastic surgery, PEEK implants are widely used, such as rhinoplasty, nasal base, eyebrow arch, chin augmentation and other implants can be directly printed after computer simulation design, compared with manual carving by doctors, the appearance is more natural, and the operation time is relatively shorter. After continuous improvement and development of new methods, it is now more widely used in areas such as the base of the nose, the arch of the eyebrows, the T-zone, the forehead, the jaw, and the chin.
Advantages of PEEK 3D printed prostheses
Good biocompatibility
PEEK material has good biocompatibility, can adapt well with human tissues, and has a low rejection rate. It can highly restore the structure of the skull, and the repaired skull is basically the same as the autologous skull, and it has excellent performance in the repair of bony defects and bony filling in the fields of orthopedics, maxillofacial surgery, plastic and cosmetic surgery. For example, in cranial repair surgery, many patients choose PEEK material, and there is no obvious rejection reaction after surgery, and the results are good.
Good physical properties
PEEK 3D printed prostheses are lightweight, strong, structurally stable, and not easily deformed. Its elastic modulus is well suited to the human skull, and even if there is a gap between the skull repair and the skull, it will slowly decrease and heal over time during the patient's postoperative recovery. At the same time, PEEK material has the characteristics of high temperature resistance, chemical resistance, fatigue resistance, excellent mechanical properties, strong impact resistance, good protective performance, and high postoperative comfort, which has gradually become a new trend of cranial repair materials.
There is no effect on medical examinations
PEEK material transmits light to X-rays and has no artifacts for CT and MRI. This advantage is important in medical imaging examinations, as it avoids the problem of artifacts in the material that can affect the test results. For example, in craniomaxillofacial surgery, the use of PEEK prostheses will not affect the subsequent medical examination in surgery such as the modification of zygomatic bones and zygomatic arches and the repair of mandibular angles, which provides convenience for doctors to accurately judge the patient's condition.
The appearance is natural, and the surgery time is short
Through computer simulation, PEEK 3D printed prostheses look natural in appearance. According to the patient's facial structure data, the prosthesis fits perfectly with the patient's body, the excessive connection is natural, the chin is fuller and three-dimensional, and the facial shape is improved. At the same time, the operation time is relatively shorter, which improves the efficiency of the operation. For example, in rhinoplasty, nasal base, eyebrow arch, chin augmentation and other surgeries, compared with the doctor's hand-carving, the printed shape of PEEK prosthesis is more natural, and the operation time is greatly shortened.
Areas of application for PEEK 3D printed prostheses
Orthopedic applications
PEEK 3D printed prostheses play an important role in the orthopedic field. Due to its chemical stability, high structural strength and conformity with skeletal mechanical properties, it is an excellent material for orthopedic implants. It can be used for fracture fixation, providing stable support and repair for fracture patients. In the repair of craniomaxillofacial defects, PEEK material can highly restore the structure of the skull, and the repaired skull is basically the same as that of the autologous skull. For example, for some patients with severe fractures, traditional treatments may not be able to fully restore the shape and function of the bone, while PEEK 3D printed prostheses can be customized to the patient's specific situation to precisely fill in the bony defect and promote bone healing and recovery. At the same time, PEEK material has good biocompatibility, low rejection rate, and can be well integrated with human tissues, providing a strong guarantee for the recovery of patients.
Maxillofacial surgical applications
In the field of maxillofacial surgery, PEEK 3D printed prostheses are widely used in cheekbone and zygomatic arch reshaping, mandibular angle repair, etc. Using CT scans and computer simulations, doctors can tailor a PEEK prosthesis to the patient's facial structure for precise restoration. For example, for patients with dysplasia or damage to the zygomatic arch of the zygomatic bones, PEEK prostheses can be personalized to the patient's specific situation, filling in the depression and improving facial contours. In mandibular angle restoration, PEEK prostheses are characterized by their light weight, high strength, and structural stability, which allow them to provide good support and repair for the mandibular angle, restoring facial symmetry and aesthetics.
Plastic and cosmetic surgery applications
In the field of plastic and cosmetic surgery, PEEK 3D printed prostheses are increasingly used in rhinoplasty, chin augmentation and other parts. Through computer simulation design and 3D printing, doctors can create natural-looking, high-fitting implants for their patients. For example, in rhinoplasty, PEEK implants can be personalized to the patient's nose structure to fill in the bridge of the nose and make the nose more elevated and beautiful. In chin augmentation surgery, PEEK implants can be customized according to the patient's chin morphology, making the chin fuller and more three-dimensional, improving facial proportions. At the same time, PEEK material has good biocompatibility, low rejection rate, fast postoperative recovery, and natural and long-lasting effect.
Applications in other fields
In addition to orthopedics, maxillofacial surgery and plastic and cosmetic surgery, PEEK 3D printed prostheses have also been explored and applied in other fields. For example, when it comes to intervertebral fusion devices and joint prostheses, the biocompatibility, corrosion resistance, and mechanical properties of PEEK material make it a potentially ideal material. At present, some research institutions and enterprises are actively exploring the application of PEEK 3D printing in these fields to meet the needs of different patients. Although the application in these fields is still in the exploratory stage, with the continuous advancement and development of technology, PEEK 3D printed prostheses are expected to play an important role in more fields.
The technical principle of PEEK 3D printed prosthesis
3D printing technology enables customization
FFF (Material Extrusion Additive Manufacturing) in 3D printing technology is a rapid prototyping technology that forms parts by melting filament materials layer by layer. It can directly read the 3D model file and output it layer by layer, without the need for molds, enabling the customized production of PEEK implants with complex geometries. For example, in the medical field, doctors can design personalized PEEK implant models based on the patient's specific condition and body structure through 3D software, and then use 3D printing technology to accurately manufacture the implant that meets the patient's needs. This customized production method greatly improves the fit and therapeutic effect of medical implants.
Parameter optimization improves performance
M3's control of parameters such as nozzle temperature is critical to improving the performance of PEEK implants. The stable control of the temperature of the M3 nozzle can reduce the viscosity of the PEEK melt, improve its flowability, and promote interfacial diffusion to enhance interlayer adhesion. It has been verified that the optimal adjustment of the extrusion magnification is related to the density and tensile strength of the printed sample, and the appropriate flow control can achieve a denser printing structure. After parameter optimization, the maximum tensile strength of PEEK implant can reach 89.8MPa, which is nearly 15.4% higher than the default parameter.
Advantages of a new generation of devices
In the case of the M3, it has a number of advantages. The next-generation heating system ensures that the PEEK material is temperature-stable throughout the printing process, ensuring that the material can withstand the stress of the patient's weight and movement when manufacturing spinal implants. Precise temperature control helps reduce thermal stress and deformation and preserve the physical properties of PEEK, which is especially important when manufacturing complex-shaped, dimensionally accurate implants. High-precision printing technology allows for meticulous layer control and precise geometrical dimensioning to ensure a perfect fit for the implant and the patient's internal structure. Significantly improved crystallinity and mechanical properties of PEEK material.
Case of skull defect repair
3D printed PEEK material to repair bilateral large skull defects in a 23-year-old patient. Xiaobei was in a car accident while working in Singapore, suffered severe head trauma, underwent craniotomy to remove hematoma and decompression surgery, and suffered severe bilateral frontotemporoparietal skull defects. Becky came to the hospital for treatment. Doctors performed CT scans, collected 3D data from the skull, applied 3D printing technology to create personalized PEEK skull repair materials, and performed PEEK skull repair and plastic surgery. The operation was successfully completed, and after the operation, Xiaobei's head was restored to its original appearance, and all symptoms were significantly improved.