The bioinert nature of polyether ether ketone(PEEK)material limits the widespread clinical application of PEEK implants.Although the porous structure is considered to improve osseointegration of PEEK implants,it is ha...The bioinert nature of polyether ether ketone(PEEK)material limits the widespread clinical application of PEEK implants.Although the porous structure is considered to improve osseointegration of PEEK implants,it is hardly used due to its mechanical properties.This study investigated the combined influence of the porous structure and in vivo mechanical stimulation on implantation safety and bone growth based on finite element analysis of the biomechanical behavior of the implantation system.The combined control of pore size and screw preloads allows the porous PEEK implant to achieve good osseointegration while maintaining a relatively high safety level.A pore size of 600μm and a preload of 0.05 N·m are the optimal combination for the long-term stability of the implant,with which the safety factor of the implant is>2,and the predicted percentage of effective bone growth area of the bone-implant interface reaches 97%.For further clinical application,PEEK implants were fabricated with fused filament fabrication(FFF)three-dimensional(3D)printing,and clinical outcomes demonstrated better bone repair efficacy and long-term stability of porous PEEK implants compared to solid PEEK implants.Moreover,good osteointegration performance of 3D-printed porous PEEK implants was observed,with an average bone volume fraction>40%three months after implantation.In conclusion,3D-printed porous PEEK implants have great potential for clinical application,with validated implantation safety and good osseointegration.展开更多
Polyether ether ketone(PEEK)-based continuous glass fiber reinforced thermoplastic composite offers advantages such as high strength,electrical insulation,and heat insulation.Parts manufactured using this composite an...Polyether ether ketone(PEEK)-based continuous glass fiber reinforced thermoplastic composite offers advantages such as high strength,electrical insulation,and heat insulation.Parts manufactured using this composite and 3D printing have promising applications in aerospace,automobile,rail transit,etc.In this paper,a high-temperature melt impregnation method was used to successfully prepare the 3D printing prepreg filaments of the aforementioned composite.In the FDM 3D printing equipment,a nozzle of high thermal conductivity and wear-resistant copper alloy and a PEEK-based carbon fiber thermoplastic composite build plate with uniform temperature control were innovatively introduced to effectively improve the quality of 3D printing.The porosity of the 3D printed samples produced from the composite prepreg filament was analyzed under different printing parameters,and the mechanical properties and fracture mechanism of the printed parts were studied.The results show that the printing layer thickness,printing speed,printing temperature and build plate temperature have varying effects on the porosity of printed parts,which in turn affects tensile strength and the interlaminar shear strength(ILSS).When the printing layer thickness is 0.4 mm,printing speed is 2 mm/s,nozzle temperature is 430℃ and build plate temperature is 150℃,the tensile strength and ILSS of the composite printed parts reach their maximum values of 463.76 and 24.95 MPa,respectively.Microscopic analysis of the fracture morphology of the tensile specimens reveals that the 3D printed CGF/PEEK composite sample has three types of fracture mode,which are single filament bundle fracture,fracture mode of delamination,and fracture failure of the sample at the cross-section.The essence of the above three kinds of fracture mode is the difference of the interface bonding force of 3D printed CGF/PEEK composites.The fracture failure at the cross-section is that the continuous glass fibers in the composite are pulled out until they break,which is the main form of the failure of the composite under tensile load.The interfacial region of the composite is prone to microscopic defects such as voids and delamination during 3D printing,which become the most vulnerable link of the composite.Understanding the relationship between voids and fracture behavior lays a foundation for defect suppression and performance improvement of subsequent printed parts.展开更多
A novel steel–carbon fibre/polyetheretherketone(CF/PEEK)hybrid shaft is proposed,considering the thermal stability,negative coefficient of thermal expansion in fibre orientation,and high stiffness of CF/PEEK,which is...A novel steel–carbon fibre/polyetheretherketone(CF/PEEK)hybrid shaft is proposed,considering the thermal stability,negative coefficient of thermal expansion in fibre orientation,and high stiffness of CF/PEEK,which is expected to suppress the thermal deformation of shafts.A laser-assisted in-situ consolidation(LAC)process,together with its equipment,was developed to manufacture the hybrid shaft.Firstly,the optimal process parameters,including the laser-heated temperature and placement speed,were investigated.A maximum short-beam shear strength of 80.7 MPa was achieved when the laser-heated temperature was 500°C and the placement speed was 100 mm/s.In addition,the failure modes and the effect of environmental temperature on the CF/PEEK samples were analyzed.Both interlayer cracks and inelastic deformation failure modes were observed.The formation and propagation of cracks were further investigated through digital image correlation(DIC).Furthermore,internal defects of the CF/PEEK sample were detected using X-ray tomography scans,and a minimum porosity of 0.23%was achieved with the optimal process parameters.Finally,two steel–CF/PEEK hybrid shafts,with different fibre orientations,were manufactured based on the optimal process parameters.The surface temperature distributions and thermal deformations were investigated using a self-established deformation/temperature measurement platform.The hybrid shaft showed an 85.7%reduction in radial displacement with hoop fibre orientation and an 11.5%reduction in axial displacement with cross fibre orientation compared with the steel shaft.The results indicate that the proposed method has great potential to improve the thermal stability of hybrid shafts and the accuracy of machine tools.展开更多
基金supported by the National Key R&D Program of China(No.2023YFB4603500)the Program for Innovation Team of Shaanxi Province(No.2023-CX-TD-17)+1 种基金the Fundamental Research Funds for the Central Universitiesthe Shaanxi Province Qinchuangyuan“Scientist+Engineer”Team Construction Project(No.2022KXJ-106).
文摘The bioinert nature of polyether ether ketone(PEEK)material limits the widespread clinical application of PEEK implants.Although the porous structure is considered to improve osseointegration of PEEK implants,it is hardly used due to its mechanical properties.This study investigated the combined influence of the porous structure and in vivo mechanical stimulation on implantation safety and bone growth based on finite element analysis of the biomechanical behavior of the implantation system.The combined control of pore size and screw preloads allows the porous PEEK implant to achieve good osseointegration while maintaining a relatively high safety level.A pore size of 600μm and a preload of 0.05 N·m are the optimal combination for the long-term stability of the implant,with which the safety factor of the implant is>2,and the predicted percentage of effective bone growth area of the bone-implant interface reaches 97%.For further clinical application,PEEK implants were fabricated with fused filament fabrication(FFF)three-dimensional(3D)printing,and clinical outcomes demonstrated better bone repair efficacy and long-term stability of porous PEEK implants compared to solid PEEK implants.Moreover,good osteointegration performance of 3D-printed porous PEEK implants was observed,with an average bone volume fraction>40%three months after implantation.In conclusion,3D-printed porous PEEK implants have great potential for clinical application,with validated implantation safety and good osseointegration.
基金supported by the National Key Research and Development Program Project of China(Grant No.2018YFB1106700).
文摘Polyether ether ketone(PEEK)-based continuous glass fiber reinforced thermoplastic composite offers advantages such as high strength,electrical insulation,and heat insulation.Parts manufactured using this composite and 3D printing have promising applications in aerospace,automobile,rail transit,etc.In this paper,a high-temperature melt impregnation method was used to successfully prepare the 3D printing prepreg filaments of the aforementioned composite.In the FDM 3D printing equipment,a nozzle of high thermal conductivity and wear-resistant copper alloy and a PEEK-based carbon fiber thermoplastic composite build plate with uniform temperature control were innovatively introduced to effectively improve the quality of 3D printing.The porosity of the 3D printed samples produced from the composite prepreg filament was analyzed under different printing parameters,and the mechanical properties and fracture mechanism of the printed parts were studied.The results show that the printing layer thickness,printing speed,printing temperature and build plate temperature have varying effects on the porosity of printed parts,which in turn affects tensile strength and the interlaminar shear strength(ILSS).When the printing layer thickness is 0.4 mm,printing speed is 2 mm/s,nozzle temperature is 430℃ and build plate temperature is 150℃,the tensile strength and ILSS of the composite printed parts reach their maximum values of 463.76 and 24.95 MPa,respectively.Microscopic analysis of the fracture morphology of the tensile specimens reveals that the 3D printed CGF/PEEK composite sample has three types of fracture mode,which are single filament bundle fracture,fracture mode of delamination,and fracture failure of the sample at the cross-section.The essence of the above three kinds of fracture mode is the difference of the interface bonding force of 3D printed CGF/PEEK composites.The fracture failure at the cross-section is that the continuous glass fibers in the composite are pulled out until they break,which is the main form of the failure of the composite under tensile load.The interfacial region of the composite is prone to microscopic defects such as voids and delamination during 3D printing,which become the most vulnerable link of the composite.Understanding the relationship between voids and fracture behavior lays a foundation for defect suppression and performance improvement of subsequent printed parts.
基金supported by the National Nature Science Foundation of China(No.52175440)the Aeronautics Science Foundation of China(No.2023Z049076001)+3 种基金the Science and Technology Innovation Fund of Shanghai Aerospace(No.SAST2022-058)the Open Fund of State Key Laboratory of Mechanical Transmissions(No.SKLMT-MSKFKT-202202)the Key R&D Program of Zhejiang Province(No.2023C01058)the Experimental Technique Project of Zhejiang University(No.SYBJS202302),China.
文摘A novel steel–carbon fibre/polyetheretherketone(CF/PEEK)hybrid shaft is proposed,considering the thermal stability,negative coefficient of thermal expansion in fibre orientation,and high stiffness of CF/PEEK,which is expected to suppress the thermal deformation of shafts.A laser-assisted in-situ consolidation(LAC)process,together with its equipment,was developed to manufacture the hybrid shaft.Firstly,the optimal process parameters,including the laser-heated temperature and placement speed,were investigated.A maximum short-beam shear strength of 80.7 MPa was achieved when the laser-heated temperature was 500°C and the placement speed was 100 mm/s.In addition,the failure modes and the effect of environmental temperature on the CF/PEEK samples were analyzed.Both interlayer cracks and inelastic deformation failure modes were observed.The formation and propagation of cracks were further investigated through digital image correlation(DIC).Furthermore,internal defects of the CF/PEEK sample were detected using X-ray tomography scans,and a minimum porosity of 0.23%was achieved with the optimal process parameters.Finally,two steel–CF/PEEK hybrid shafts,with different fibre orientations,were manufactured based on the optimal process parameters.The surface temperature distributions and thermal deformations were investigated using a self-established deformation/temperature measurement platform.The hybrid shaft showed an 85.7%reduction in radial displacement with hoop fibre orientation and an 11.5%reduction in axial displacement with cross fibre orientation compared with the steel shaft.The results indicate that the proposed method has great potential to improve the thermal stability of hybrid shafts and the accuracy of machine tools.
