Creating load-bearing polymeric materials that promote tissue integration without compromising strength remains a central challenge in musculoskeletal reconstructions. Polyetheretherketone (PEEK) is a widely used polymer in orthopaedic implants due to its outstanding mechanical properties, radiolucency, and biocompatibility, yet it does not effectively osseointegrate. Current PEEK modifications improve osseointegration, but weaken PEEK’s mechanical properties. Here we report a process to selectively extrude a thin, interconnected porous surface layer from solid PEEK to enhance osseointegration. Surface extrusion seamlessly integrates the porous and solid regions, resulting in high interfacial shear strength. We show that surface porous PEEK retains the favorable tensile strength, stiffness, and fatigue properties of solid PEEK and provides a conduit for bony ingrowth. The capacity of a thin porous layer to facilitate tissue integration without substantial mechanical detriment could have major implications for the design of load-bearing implants.

Surface porous PEEK with high strength for load-bearing orthopaedic implants

249th National Meeting (2015)

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