Transactions on Additive Manufacturing Meets Medicine
Vol. 7 No. S1 (2025): Trans. AMMM Supplement
https://doi.org/10.18416/AMMM.2025.25062058

Material Properties, Structural Designs, and Printing Technologies, ID 2058

Sterilization Effects on Dimensional Accuracy of 3D-Printed Carbon Fiber-Reinforced Nylon

Main Article Content

Giles Michael Cheers (1) Department of Orthopaedics and Trauma Surgery, Musculoskeletal University Center Munich (MUM), LMU University Hospital, Munich, Germany; 2) Centre for Biomedical Technologies, Queensland University of Technology, Brisbane, Australia; 3) ARC ITTC for Multiscale 3D Imaging, Modelling and Manufacturing (M3D Innovation), Queensland University of Technology, Brisbane, Australia; 4) Faculty of Engineering, Queensland University of Technology, Brisbane, Australia), Abbey Goodwin (2) Centre for Biomedical Technologies, Queensland University of Technology, Brisbane, Australia; 4) Faculty of Engineering, Queensland University of Technology, Brisbane, Australia), Andreas Heede (5) Stryker Trauma GmbH), Jana Milite (5) Stryker Trauma GmbH), Melissa Johnston (4) Faculty of Engineering, Queensland University of Technology, Brisbane, Australia), Anthony Morris (6) Design and Fabrication Research Facility, Queensland University of Technology, Brisbane, QLD, Australia), Marie-Luise Wille (2) Centre for Biomedical Technologies, Queensland University of Technology, Brisbane, Australia; 3) ARC ITTC for Multiscale 3D Imaging, Modelling and Manufacturing (M3D Innovation), Queensland University of Technology, Brisbane, Australia ; 4) Faculty of Engineering, Queensland University of Technology, Brisbane, Australia), Paige Little (2) Centre for Biomedical Technologies, Queensland University of Technology, Brisbane, Australia; 3) ARC ITTC for Multiscale 3D Imaging, Modelling and Manufacturing (M3D Innovation), Queensland University of Technology, Brisbane, Australia; 4) Faculty of Engineering, Queensland University of Technology, Brisbane, Australia; 7) Biomechanics and Spine Research Group (BSRG), Queensland University of Technology, Brisbane, Australia), Sinduja Suresh (2) Centre for Biomedical Technologies, Queensland University of Technology, Brisbane, Australia; 3) ARC ITTC for Multiscale 3D Imaging, Modelling and Manufacturing (M3D Innovation), Queensland University of Technology, Brisbane, Australia; 4) Faculty of Engineering, Queensland University of Technology, Brisbane, Australia; 7) Biomechanics and Spine Research Group (BSRG), Queensland University of Technology, Brisbane, Australia)

Copyright (c) 2025 Giles Michael Cheers, Abbey Goodwin, Andreas Heede, Jana Milite, Melissa Johnston, Anthony Morris, Marie-Luise Wille, Paige Little, Sinduja Suresh

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This work is licensed under a Creative Commons Attribution 4.0 International License.

Abstract

Ensuring dimensional stability of additively manufactured (AM) medical components during sterilization is a critical yet understudied challenge. This study investigates the influence of geometry, continuous carbon fiber (CCF) reinforcement, and sterilization methods on the dimensional accuracy of fused filament fabricated (FFF) CCF reinforced nylon composites. 40 specimens of standard (ASTM D3039) and non-standard geometries were produced using Onyx®, both with and without CCF reinforcement. Printed samples were subjected to ethanol disinfection or steam autoclaving under ISO guidelines. MicroCT imaging was conducted before and after sterilization, and 3D geometric analysis was performed.


Sterilization type did not affect surface deviation post treatment (p=0.1643), but deviations were primarily influenced by part geometry (p<0.001) and CCF reinforcement (p=0.0031). Non-standard geometries with concentric fiber paths demonstrated significantly greater resistance to warping compared to standard rectilinear patterns (p<0.001). Standard geometry without CCF reinforcement showed the highest deviations of all tested groups with a max deviation of 0.5 mm on average. Void fraction analysis further indicated that both, geometry and CCF reinforcement, contribute to porosity variations (p= 0.0038; p= 0.0044), with reinforced components displaying marginally higher (>1%) void fractions.


These findings emphasize that optimizing print resolution, reinforcement strategies, and geometric design can help define production guidelines for 3D-printed composite implants compatible with sterilization protocols in healthcare. Future research should explore alternative sterilization techniques and advanced composite materials to further refine the applicability of AM in medical device manufacturing.

Article Details

How to Cite

Cheers, G. M., Goodwin, A., Heede, A., Milite, J., Johnston, M., Morris, A., … Suresh, S. (2025). Sterilization Effects on Dimensional Accuracy of 3D-Printed Carbon Fiber-Reinforced Nylon. Transactions on Additive Manufacturing Meets Medicine, 7(S1), 2058. https://doi.org/10.18416/AMMM.2025.25062058

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