A novel single-step manufacturing platform for patient-specific PEEK implants via FFF and in situ plasma biofunctionalization

Abstract

Additive manufacturing enables the production of patient-specific medical implants with complex geometries. However, many high-performance polymers used in clinical applications, such as polyetheretherketone (PEEK), are inherently bioinert and susceptible to implant-associated infections, limiting long-term clinical performance. Conventional strategies to overcome these limitations typically rely on post-processing surface treatments, which increase manufacturing complexity, additional handling steps, and regulatory burden.

We present an integrated additive manufacturing platform that combines fused filament fabrication (FFF) with in situ plasma-based surface functionalization, enabling the simultaneous fabrication and biofunctionalization of polymer implants within a single, continuous process. The integrated vacuum arc plasma coating step allows direct biofunctionalization of the printed components. Metal-based coatings exhibit varying degrees of antimicrobial activity, while some metal-oxides such as TiO? can enhance the attachment of bone cells. In addition, the printed parts may benefit from the vacuum environment in terms of improved mechanical properties and the cleanroom-like conditions provided by the vacuum.

Overall, this integrated printing-and-coating technology represents a versatile manufacturing paradigm for next-generation medical implants that require both customized geometry and tailored biological functionality, with potential applications in reconstructive medicine.