Phase-Field Modeling and Simulation of High-Strength Porous Polymer Fabrication Via Immiscible Polymer Blending for Bone Implants

Abstract Polyether ether ketone (PEEK) has emerged as a popular choice for medical implants, with significant research focusing on developing porous PEEK structures to improve cell adhesion and ingrowth. A novel fabrication process for porous PEEK implants was recently introduced using immiscible polymer blending with polyether sulfone (PES) as a sacrificial phase. In this study, a computational phase separation model for PEEK/PES immiscible blends is developed by integrating the phase-field theory and thermo-fluid dynamics. Physical properties of the polymers were incorporated, and both 2D and 3D simulations were conducted. The 3D model was validated against experimental data, providing a quantitative understanding of the PEEK/PES phase separation process. By comparing with experimental results, the model enables the estimation of material properties that are challenging to measure and offers critical insights for optimizing the PEEK implant fabrication process.