Revolutionizing healthcare materials: Innovations in processing, advancements, and challenges for enhanced medical device integration and performance

Cutting-edge materials have transformed the fabrication of medical devices and implants. However, the processing used to create these materials impacts their mechanical, physical, and biological characteristics, preventing effective integration. This study is intended to provide a detailed analysis of healthcare materials processing techniques, stressing healthcare-specific material requirements, such as biocompatibility, mechanical strength, corrosion resistance, stabilizability, and bioactivity, followed by classifying these processing methods as “ordinary” and “edge-cutting” methods. The consequences of each processing on the material, as well as the benefits, drawbacks, and recent developments of each technique, are also aimed to be concluded. The study also aimed to explore how process factors affect product qualities. The articles are collected from the Scopus and Web of Science databases using the search strings “Advance Material,” “Material Processing,” “Healthcare,” and “HealthCare Application.” The assessment of the selected literature has been done in accordance with the objectives. The assessment emphasizes quality assurance and regulatory compliance by stressing the need for quality assurance, characterization, and testing for medical devices and implants. Processes such as polishing, etching, and coatings improve biocompatibility and reduce infection risk, according to the findings. It was also concluded that cutting-edge processing methods such as additive manufacturing (3D printing) and electrospinning provide exact control over material composition, structure, and porosity, making them ideal for many clinical applications.