Additively manufacturing bioimitated multi-layered medical composite trauma plates

An updated Additive Manufacture (AM) technology to produce Bioimitated Medical Composite Trauma Plates (BMCTP) is introduced in this paper. It aims to produce bioimitated multi-layered and continuous fibre reinforced medical composites with enhanced damage resilience and biomechanics compatibility for promptly recovering fractured bones. The BMCTP samples are produced by a 3D composite printer and validated using mechanical bending test and modelling analysis. The overall mechanical and fracture properties of the BMCTP samples are conducted based on the bending test outcomes. Research results have shown that the investigated BMCTP sample reaches the loading capacity of 1 kN under three-point bending. This is approximately 2 times higher than the required load that occurs when using this medical trauma plate in surgery. The biomechanics compatibility of the trauma construct has been reflected in the design and AM process. It allows the fractured bone to undertake healing required compressive strains (1%–10%) for mechanically stimulating the healing of the fractured bone. Compared to the BMCTP sample without surface treatment, the damage resistance of the surface-treated one increases by 19%. This technology provides a highly cost-effective approach to produce future medical composite trauma plates for possible applications in treatment and prosthetics in orthopedics and traumatology.