Studies on Polymer Materials for Bone Reconstruction using Additive Manufacturing Technology

AbstractAdditive Manufacturing (AM), particularly Fused Deposition Modeling (FDM), hasrevolutionized the biomedical field by enabling the fabrication of patient-specific, complexgeometries that are unattainable through traditional manufacturing. This reviewcomprehensively examines the convergence of FDM with two pivotal biomedical polymers:Polyetheretherketone (PEEK), a high-performance polymer known for its exceptionalstrength and biocompatibility, and Polylactic Acid (PLA), a biodegradable polymer valuedfor its resorbability and ease of printing. The central thesis of this work is that the mechanicalperformance and biological functionality of FDM-fabricated parts are intrinsically governedby a complex interplay of process parameters. This article synthesizes the current state ofknowledge, detailing the fundamental principles of FDM, the material properties of PEEKand PLA, and the compelling rationale for their combination into composite systems. Asignificant portion is dedicated to the formidable challenges posed by their thermalincompatibility and immiscibility. The review systematically analyzes the influence ofcritical FDM parameters—such as nozzle temperature, chamber temperature, layer height,and raster angle—on the mechanical anisotropy, crystallinity, and interlayer bonding of thesematerials. Furthermore, it consolidates research on innovative strategies to overcome thesehurdles, including multi-material printing, compatibilization, and the use of fillers likehydroxyapatite. Finally, the review identifies critical research gaps and proposes a structuredpathway for future work, emphasizing the need for systematic parameter optimization usingDesign of Experiments (DOE) to unlock the full potential of PEEK/PLA composites for nextgeneration, load-bearing, and partially resorbable biomedical implants.