Carbon Fiber-reinforced Polyetheretherketone Research Articles

Evaluation of the Biomechanical Effects and Stability of Titanium and Carbon Fiber-Reinforced Polyetheretherketone Mini Plates in Le Fort I Advancement Osteotomy Fixation Using Finite Element Analysis.

This study aimed to investigate the biomechanical properties of 60% carbon fiber-reinforced polyetheretherketone (Cfr-PEEK), which exhibits high mechanical strength and can address the limitations of titanium mini plates used in Le Fort I osteotomy. Models were created using the FEA method based on tomography images of adult individuals. A 5 mm maxillary advancement was applied to the models following Le Fort I osteotomy. Mini plates made of titanium and 60% Cfr-PEEK were used. Support was provided by the nasomaxillary and zygomaticomaxillary buttresses to fix a total of four L-shaped mini plates. Oblique loads of 125 N, directed from palatal to buccal, and a total of 250 N compression loads were applied to the central fossa of the premolar and molar teeth in the maxillary model at a 30° angle relative to the long axis of the teeth. Displacement values at the osteotomy line, Von Mises stresses in the mini plate-screws, and principal stresses in the bone were compared. Examination of stress values in the fixation systems of the models revealed higher stress values in the Cfr-PEEK model compared to the titanium model. However, these stresses did not reach levels that would deform the Cfr-PEEK fixation systems. Stress and displacement values in the bone were lower in the Cfr-PEEK model compared to the titanium model. According to the findings of our study, Cfr-PEEK represents a viable alternative to titanium for mini plate material in Le Fort I osteotomy, offering biomechanical advantages.

Ultra-high-rate Manufacturing of Thermoplastic Window Plug using Hybrid Overmolding

Highly loaded complex parts are machined from a solid block of metal by removing material through cutting, boring, drilling, and grinding to obtain the three-dimensional shape. Most cases, this involves removing as much as 80 percent of the material from a billet, which is time-consuming and inefficient considering the cost of the materials. Alternatively, these complex parts can be manufactured using hybrid overmolding process which involves injecting plastics over a reinforced substrate with continuous fiber-reinforcement eliminating subtractive machining or joining of multiple parts. The substrate is typically heated using an infrared (IR) oven and preformed over a solid mold to a three-dimensional shape using thermoforming. Injection overmolding material can also be reinforced with discontinuous fibers based on the design requirements. Both thermoforming and injection molding are matured automotive ultra-high-rate manufacturing processes. Adopting these technologies to aerospace requires advanced aerospace-grade thermoplastic material systems and developing the hybrid overmolding process that combines both thermoforming and injection molding processes. Material compatibility is one of the key enablers for the fusion across the overmolded interfaces. To demonstrate the overmolding technology for an aerospace application, Victrex AE250 low-melt polyaryletherketone (LM-PAEK) system reinforced with AS4 fibers and a 30% carbon fiber-reinforced polyetheretherketone (PEEK) were used to overmold aircraft window plugs to be used for cargo conversion of passenger aircraft. The fully automated overmolding process was demonstrated using KraussMaffei multi-robotic thermoforming and injection molding system. Thermal and mechanical test evaluations were employed to assess the material compatibility and overall part quality. Photomicrographs and flexure tests conducted on test samples extracted from the window plugs indicated satisfactory fusion across the overmolded interface and optimized holding of PEEK materials.

In-Plane Cyclic Mechanical Properties of CF/PEEK/TPU Flexible Composite with Zero Poisson Ratio.

This paper presents the in-plane deformation and cyclic mechanical properties of CF/PEEK (Carbon Fiber-Reinforced Polyetheretherketone)-reinforced TPU (thermoplastic polyurethanes) flexible composites with a zero Poisson ratio. A novel CF/PEEK honeycomb reinforcement with a zero Poisson ratio was fabricated by using 3D-printing technology. Then, TPU was bonded in the two sides of the CF/PEEK honeycomb reinforcement. The in-plane deformation ability and cyclic mechanical properties were evaluated. The results show that the zero Poisson ratio flexible composite can achieve a large in-plane plastic deformation of more than 50% and can better maintain the zero Poisson ratio superstructure. By collecting and comparing the mechanical characteristic values of the CF/PEEK flexible composite under a cyclic load, the CF/PEEK flexible composite MH22-t0.6-CT has the best structural stability. The length of the structure was increased by about 12.53%. By studying the deformation mechanism and failure mechanisms of the flexible composites, the in-plane recyclability of the flexible composites was evaluated, which provides the basic research basis for large-scale in-plane deformation composites.

Nanofiber‐Coated CF/PEEK Composite: Boosting Osteogenesis for Enhanced Bone Grafting

AbstractThis study presents the fabrication of carbon‐fiber‐reinforced polyetheretherketone (CF/PEEK) by 3D printing, which is subsequently coated with elastic nanofibers by electrospinning. CF/PEEK is an FDA‐approved implantable material possessing excellent mechanical properties similar to those of human cortical bone. As such, it is a prime candidate for replacing conventional metallic implants. However, it is limited by its bioinertness and inferior osteogenic properties. In this study, CF/PEEK is engineered to have improved hydrophilic properties and generated micro/nano‐topographical structures on its surface. This is achieved by electrospinning directly onto the 3D‐printed CF/PEEK with fibers incorporating hydroxyapatite particles and gelatin. The results show that the micro‐/nano‐topographical CF/PEEK demonstrates a significant increase in mineralizing potential compared to non‐coated implants, where no mineralized matrix is observed. These fiber coating modifications to CF/PEEK are a promising and important step forward in the improvement of in vivo implant‐bone osteointegration.

A novel printing strategy to fabricate polyetheretherketone (PEEK)-based composites via hollow filaments filled with multiple reinforcements

ABSTRACT Polyetheretherketone (PEEK)-based composites fabricated by material extrusion (ME) have attracted broad research attention; however, the complex pre-made composite filament process makes them inflexible. In this work, a novel composite printing strategy was proposed by filling composite powder into hollow filaments to construct composite filaments for printing. This strategy eliminated the screw extrusion composite filament process and fabricated composite parts directly using composite powders. Hydroxyapatite-reinforced polyetheretherketone (HA-PEEK) and carbon fibre-reinforced polyetheretherketone (CF-PEEK) composite specimens were fabricated based on the proposed printing method, and their chemical, physical, and mechanical properties were investigated. To improve the mechanical performance of the specimens, annealing was conducted. It was found that the printed composite specimens had excellent mechanical properties. The highest flexural strengths of the 10% HA-PEEK-R and 5% CF-PEEK-R specimens were detected as 352.9 and 399.4 MPa, respectively. The compression strengths of the 10% HA-PEEK-R and 20% CF-PEEK-R specimens peaked, representing 123.0 and 137.2 MPa, respectively. Furthermore, adding different functional reinforcement fillers or various filler contents to different segments of hollow filaments, sandwich structures and gradient structures were successfully fabricated.

3D-Printed high performance PEEK/CF-PEEK polymer composites—An investigation on microstructural characteristics and mechanical performance

This study investigates the microstructural characteristics and mechanical properties of 3D-printed polyether ether ketone (PEEK) and carbon fiber-reinforced PEEK (PEEK CF20) composites. Using a specifically optimized 3D printing process parametric condition, samples of pure PEEK and PEEK CF20 (containing 20% carbon fiber) were fabricated. Mechanical properties were estimated by tensile, flexural, and interlaminar shear strength (ILSS) tests, performed as per ISO and DIN standards. Results indicated that PEEK CF20 exhibits significantly enhanced mechanical properties compared to pure PEEK. The tensile strength of PEEK CF20 was 81.069 MPa, compared to 76.070 MPa for pure PEEK. Maximum load values were 1456.608 N for PEEK CF20 and 1286.137 N for pure PEEK, while ILSS values were 15.76 MPa for PEEK CF20 and 11.82 MPa for pure PEEK. Microstructural analysis through field emission scanning electron microscopy (FESEM) revealed that PEEK CF20 had better fiber-matrix bonding and fewer defects compared to pure PEEK.

Laser-assisted automated tape laying: Effects of placement rate and heated tooling on layer bonding and tensile properties

This paper investigates the processing parameters placement rate and tooling temperature of laser-assisted automated tape laying (ATL). Plates with carbon fiber-reinforced polyether ether ketone (CF/PEEK) were produced at 6 m/min, 9 m/min and 18 m/min, and 23°C and 250°C tooling temperature, respectively. Correlations of processing conditions with micrographs, void content, thickness, the degree of crystallinity and the shear strength of the compression shear test, including a fractographic analysis, were derived. Processing conditions that increase the degree of crystallinity were only found to improve the compression shear strength at 6 m/min placement rates, primarily due to a void content below 3.4 % and degree of crystallinity above 26 %. The fractographic analysis derived from the compression shear test revealed a strong correlation between the degree of crystallinity and the size of ductile drawings. In contrast, the transverse tensile test showed no influences on the ATL processing conditions, whereas the tensile strength in fiber direction decreased by 11 % from a placement rate of 6 m/min to 18 m/min. ATL with a 250°C tooling temperature increased the strengths by 14 % compared to those at room temperature. A further tensile strength improvement of 0° and 90° to 1754 MPa and 75 MPa was obtained by a subsequent out-of-autoclave consolidation using vacuum bagging.

Impact of instrumentation material on local recurrence: a case-matched series using carbon fiber-PEEK vs. titanium.

Spine metastases are a major burden of oncologic care, contributing to substantial morbidity. A well-established treatment paradigm for patients with metastatic epidural spinal cord compression includes separation surgery followed by stereotactic body radiotherapy (SBRT). Innovations in implant technology have brought about the incorporation of Carbon fiber-reinforced polyetheretherketone (CFR-PEEK) instrumentation for spinal fixation. We present our experience of CFR-PEEK instrumentation, comparing outcomes and complication profiles with a matched cohort of titanium instrumented cases for spine metastatic disease. Oncology patients who underwent spinal fusion for metastatic spine disease from 2012 to 2023 were retrospectively reviewed. Ninety-nine cases with CFR-PEEK fusions were case-control matched with 50 titanium controls (2:1 ratio) based upon primary tumor type and spinal instability neoplastic score (SINS) location. Demographic, clinical, radiographic and progression free survival (PFS) were analyzed. In the study years, 263 patients underwent spinal decompression and fusion, for which 148 patients met predetermined inclusion criteria. Of these, 49 had titanium instrumentation, and 99 had CFR-PEEK. Complication profiles, including hardware failure and infection were similar between the groups. There was no significant difference in PFS between all CFR-PEEK and titanium patients (143 days versus 214 days; p = 0.41). When comparing patients in which recurrence was noted, CFR-PEEK patients had recurrence detected two times earlier than titanium patients (94 days versus 189 days; p = 0.013). In this case matched cohort, CFR-PEEK demonstrated decreased overall PFS suggestive of earlier local recurrence identification. Long-term studies are warranted for better evaluation of the impact on survival and systemic disease progression.

Nonmetallic Carbon Fiber-Reinforced Polyetheretherketone Implants Vs Titanium Implants: Analysis of Clinical Outcomes and Influence on Postoperative Radiotherapy Planning in Metastatic Spine Tumor Surgery.

Titanium has been the conventional implant material of choice for fixation in both primary and metastatic spine tumor surgeries (MSTS). However, these implants result in artifact generation during postoperative computed tomography or magnetic resonance imaging, resulting in poor planning of radiotherapy (RT) and suboptimal tumor surveillance. Carbon fiber-reinforced polyetheretherketone (CFR-PEEK) implants have gained momentum for instrumentation in MSTS due to their radiolucent properties. In this study, the perioperative outcomes, postoperative imaging artifacts, and dosimetric data of CFR-PEEK implants to titanium implants were compared to assess for potential benefits in postoperative RT planning in patients undergoing MSTS. This is a retrospective study involving 62 patients who underwent operations for MSTS. The cohort of CFR-PEEK fixations (n = 20) was compared with a series of patients operated using titanium implants (n = 42). Patient-related data, including demographics, tumor pathology and extent of morbidity, intraoperative data, functional outcome, and RT-related data, were recorded for both groups. Primary outcome measures for RT data were amount of artifact generated on postoperative imaging and the time taken to contour them. All patients were followed up postoperatively for a minimum of 2 years or until death, whichever was earlier. Both groups had similar clinical outcomes for pain and overall survival predictability preoperatively (P = 0.786). The mean number of levels instrumented by titanium screws was 5.69 ± 2.64, while for CFR-PEEK screws it was 4.26 ± 1.05. Mean volume of artifact generated during postoperative computed tomography was 73.4 ± 50.43 mm3 in the titanium group and 20.0 ± 20.7 mm3 in the CFR-PEEK group (P < 0.001). The mean time taken to contour the artifacts was 17.3 ± 5.84 minutes in titanium group and 9.60 ± 7.17 minutes in CFR-PEEK group (P = 0.049). Our study confirms that CFR-PEEK screws significantly reduce artifact generation and the time taken to contour them during postoperative RT planning while delivering equivalent clinical and functional outcomes as compared with standard titanium implants.

Intelligent Supramolecular Modification for Implants: Endogenous Regulation of Bone Defect Repair in Osteoporosis.

Addressing osteoporosis-related bone defects, a supramolecular strategy is innovated for modifying carbon fiber reinforced polyether ether ketone (CF/PEEK) composites. By covalently attaching intelligent macromolecules via in situ RAFT polymerization, leveraging the unique pathological microenvironment in patients with iron-overloaded osteoporosis, intelligent supramolecular modified implant surface possesses multiple endogenous modulation capabilities. After implantation, surface brush-like macromolecules initially resist macrophage adhesion, thereby reducing the level of immune inflammation. Over time, the molecular chains undergo conformational changes due to Fe (III) mediated supramolecular self-assembly, transforming into mechanistic signals. These signals are then specifically transmitted to pre-osteoblast cell through the binding capacity of the KRSR short peptide at the molecular terminus, induced their osteogenic differentiation via the YAP/β-catenin signaling axis. Furthermore, osteoblasts secrete alkaline phosphatase (ALP), which significantly hydrolyzes phosphate ester bonds in surface macromolecular side groups, resulting in the release of alendronate (ALN). This process further improves the local osteoporotic microenvironment. This intelligent surface modification tailors bone repair to individual conditions, automatically realize multiple endogenous regulation once implanted, and truly realize spontaneous activation of a series of responses conducive to bone repair in vivo. It is evidenced by improved bone regeneration in iron-overloaded osteoporotic rabbits and supported by in vitro validations.

Interfacial crystallization behavior and properties of T1100-grade carbon fiber reinforced PEEK composites

As a semi-crystalline resin, the crystallization behavior of Polyether ether ketone at the interface between carbon fiber and resin matrix profoundly affects the interfacial properties of carbon fiber-reinforced PEEK composite. Therefore, the research on the interfacial crystallization behavior of CF/PEEK composite is of great significance. Aiming at Chinese-made T1100-grade carbon fiber and PEEK resin matrix, the effects of cooling rate and sizing agent on the interfacial crystallization behavior of T1100-grade carbon fiber/PEEK were studied by POM and DSC, and the IFSS was tested by microdebond. The experimental results show that the increase of the cooling rate and the removal of the sizing agent can improve the nucleation ability of PEEK and promote the interfacial crystallization of PEEK. PEEK starts to form transcrystallization, when the nucleus density is increased to about 0.07/μm. The interfacial crystallization behavior has an effect on the interfacial properties. The IFSS increases with increasing cooling rate and removal of sizing agent.

Compressive properties and biocompatibility of additively manufactured lattice structures by using bioactive materials

Porous bioactive materials were widely used in orthopedic implant fields because of their excellent mechanical properties and porous spaces. However, most porous types are predominantly stacked in two-dimensional configurations, which significantly limits their mechanical property range and adversely affects the modulus matching between the porous implants and surrounding bone tissues. Hence, various lattice structures were prepared using 3D printing technology with bioactive materials, and characterized by mechanical and biological tests. Numerical simulations were conducted to analyze the effect of relative density and geometric parameters on the equivalent compressive properties of the lattice structures. The results showed that the lattice structure exhibited a broad elastic modulus range, which can be adjusted to align with the mechanical properties of human cortical and cancellous bones, thereby helping to mitigate stress shielding in orthopedic implants. The biocompatibility of the 3D-printed solid materials was assessed in vitro using a cell counting assay kit-8 (CCK-8). The results indicated that poly-ether-ether-ketone (PEEK), carbon fiber reinforced PEEK (CFR/PEEK), nylon, and titanium (Ti) alloy all exhibited good biocompatibility, with no significant differences observed among the four materials. This study further enhances the understanding of bioactive lattice structures in the biomedical field and offers new possibilities for orthopedic repair.

Clinical performance of implanted devices used in surgical treatment of patients with spinal tumors: a systematic review

PurposeImplanted devices used in metastatic spine tumor surgery (MSTS) include pedicle screws, fixation plates, fixation rods, and interbody devices. A material to be used to fabricate any of these devices should possess an array of properties, which include biocompatibility, no toxicity, bioactivity, low wear rate, low to moderate incidence of artifacts during imaging, tensile strength and modulus that are comparable to those of cortical bone, high fatigue strength/long fatigue life, minimal or no negative impact on radiotherapy (RT) planning and delivery, and high capability for fusion to the contiguous bone. The shortcomings of Ti6Al4V alloy for these applications with respect to these desirable properties are well recognized, opening the field for an investigation about novel biomaterials that could replace the current gold standard. Previously published reviews on this topic have exhibited significant shortcomings in the studies they included, such as a small, heterogenous sample size and the lack of a cost-benefit analysis, extremely useful to understand the practical possibility of applying a novel material on a large scale. Therefore, this review aims to collect information about the clinical performance of these biomaterials from the most recent literature, with the objective of deliberating which could potentially be better than titanium in the future, with particular attention to safety, artifact production and radiotherapy planning interference. The significant promise showed by analyzing the clinical performance of these devices warrants further research through prospective studies with a larger sample size also taking into account each aspect of the production and use of such materials.MethodsThe Preferred Reporting Items for Systematic reviews and Meta-Analyses (PRISMA) guidelines were used to improve the reporting of the review. The search was performed from March 2022 to September 2023.ResultsAt the end of the screening process, 20 articles were considered eligible for this study. Polyetheretherketone (PEEK), Carbon-fibre reinforced polyetheretherketone (CFR-PEEK), long carbon fiber reinforced polymer (LCFRP), Polymethylmethacrylate (PMMA), and carbon screw and rods were used in the included studies.ConclusionCFR-PEEK displays a noninferior safety and efficacy profile to titanium implanted devices. However, it also has other advantages. By decreasing artifact production, it is able to increase detection of local tumor recurrence and decrease radiotherapy dose perturbation, ultimately bettering prognosis for patients necessitating adjuvant treatment. Nonetheless, its drawbacks have not been explored fully and still require further investigation in future studies. This does not exclude the fact that CFR-PEEK could be a valid alternative to titanium in the near future.

An Experimental Study on the Thermomechanical Coupling Effects of Carbon-Fiber-Reinforced Polyetheretherketone under Dynamic Impact.

Carbon-fiber-reinforced polyetheretherketone (CF/PEEK) composites are widely utilized in aerospace, medical devices, and automotive industries, renowned for their superior mechanical properties and high-temperature resistance. Despite these advantages, the thermomechanical coupling behavior of CF/PEEK under dynamic loading conditions is not well understood. This study aims to explore the thermomechanical coupling effects of CF/PEEK at elevated strain rates, employing Hopkinson bar impact tests and scanning electron microscopy (SEM) for detailed characterization. Our findings indicate that an increase in temperature led to significant reductions in the yield strength, peak stress, and specific energy absorption of CF/PEEK, while fracture strain had no significant effect. For instance, at 200 °C, the yield strength, peak stress, and specific energy absorption decreased by 39%, 37%, and 38%, respectively, compared to their values at 20 °C. Furthermore, as the strain rate increased, the yield strength, peak stress, specific energy absorption, and fracture strain all exhibited strain-hardening effects. However, as the strain rate further increased, above 4000 s-1, the enhancing effect of the strain rate on the yield strength and peak stress gradually diminished. The interaction of the temperature and strain rate significantly affected the mechanical performance of CF/PEEK under high-speed impact conditions. While the strain rate generally enhanced these properties, the strain-hardening effect on the yield strength weakened as the temperature increased, and both the temperature and strain rate contributed to the increase in specific energy absorption. Microdamage mechanism analysis revealed that interface debonding and sliding between the fibers and the matrix were more pronounced under static compression than under dynamic compression, thereby diminishing the efficiency of stress transfer. Additionally, higher temperatures caused the PEEK matrix to soften and exhibit increased viscoelastic behavior, which in turn affected the material's toughness and the mechanisms of stress transfer. These insights hold substantial engineering significance, particularly for the optimization of CF/PEEK composite design and applications in extreme environments.

Thermo-oxidative crosslinking of carbon fiber reinforced PEEK (Polyetheretherketone) for additive manufactured ceramic matrix composites

Carbon fiber reinforced polyetheretherketone (CF-PEEK) samples were fabricated using material extrusion. These additive manufactured green bodies are later processed to their final application as ceramic matrix composites (CMC) by the liquid silicon infiltration (LSI) route. Past studies showed that the application of material extrusion for the fabrication of CMC requires an additional stabilization-step after 3D-printing in order to prevent the remelting of CF-PEEK during the high temperature process of pyrolysis. The thermally induced crosslinking of the CF-PEEK parts ensured shape accuracy and avoided remelting during the pyrolysis afterwards but is limited by the melting temperature of PEEK (T m ∼ 343 °C). The study revealed a correlation between the annealing conditions time and temperature and the degree of crosslinking. Based on the analytical results from differential scanning calorimetry (DSC), a kinetic model was calculated, allowing predictions in dependence of the annealing temperature and time. Rheological and shape stability investigations of thermally annealed specimens verified the analytic results. The main findings of the study highlight an increasing degree of crosslinking with increasing annealing temperature and time.

Bone healing under different lay-up configuration of carbon fiber-reinforced PEEK composite plates.

Secondary healing of fractured bones requires an application of an appropriate fixator. In general, steel or titanium devices are used mostly. However, in recent years, composite structures arise as an attractive alternative due to high strength to weight ratio and other advantages like, for example, radiolucency. According to Food and Drug Administration (FDA), the only unidirectionally reinforced composite allowed to be implanted in human bodies is carbon fiber (CF)-reinforced poly-ether-ether-ketone (PEEK). In this work, the healing process of long bone assembled with CF/PEEK plates with cross- and angle-ply lay-up configurations is studied in the framework of finite element method. The healing is simulated by making use of the mechanoregulation model basing on the Prendergast theory. Cells transformation is determined by the octahedral shear strain and interstitial fluid velocity. The process runs iteratively assuming single load cycle each day. The fracture is subjected to axial and transverse forces. In the computations, the Abaqus program is used. It is shown that the angle-ply lamination scheme of CF/PEEK composite seems to provide better conditions for the transformation of the soft callus into the bone tissue.

Pomegranate-like ZnMn2O4 nanospheres/carbon fiber network for interface enhancement structure-function PEEK composites with good electromagnetic interference shielding and thermal conductivity

The functionalization of structural carbon fiber reinforced polymer (CFRP) composites remains a significant challenge. In this work, the integration of structure-function was achieved in carbon fiber reinforced PEEK (CF/PEEK) composite by introducing a ZnMn2O4-based interface with the functionalities of electromagnetic interference (EMI) shielding and thermal conductivity (TC). The ZnMn2O4 nanospheres/CF network was constructed by introducing ZnMn2O4 nanospheres on the CF surface, realizing a significantly strengthened composite interface. Notably, the interlayer shear strength (ILSS) of the UCF-Z125/PEEK composite has reached 85.38 MPa, marking a 47.51 % increase over the Unsized CF/PEEK composite. In addition, the EMI shielding and the TC performances of the CF/PEEK composite have also improved, with the EMI shielding of the composite enhanced by 54.67 % and the through-plane TC increased by 47.17 %. This structure-function integrated composite can be used not only as structural materials in aerospace applications but also as high-performance bifunctional materials in semiconductor and artificial intelligence industries.

Mechanical property of powder bed fusion printed carbon fiber reinforced polyetheretherketone and enhanced interlayer strength by post‐processing

AbstractAdditive Manufacturing (AM) of carbon fiber reinforced polyetheretherketone (CF/PEEK) composites with excellent performance by Powder Bed Fusion (PBF) has great potential in the applications where high strength and high service temperature are required. However, the reinforcement mechanisms of CF/PEEK composites based on the PBF process are complex and show significant differences from traditional processing methods. In this paper, the mechanical properties of CF/PEEK prepared by PBF were investigated. The results showed that its X‐axis tensile strength and modulus were approximately equal to or a bit lower than the theoretical value with randomly distributed CF, but much lower than the theoretical value with unidirectional distribution of CF in composites. Meanwhile, mechanical strength anisotropy was observed. The composites' Y‐axis tensile strength was slightly lower than X‐axis, and the lowest strength existed in Z‐axis. To improve the weak Z‐axis strength, post‐processing of annealing and solvent‐induced crystallization were carried out, and the Z‐axis tensile strength of post‐processed parts reached 50 MPa, which was 62% higher than untreated samples. Consequently, suitable CF and proper post‐ processing for AM of high strength CF/PEEK were proposed, which would promote the industrial application of this technology.Highlights The effect of CF on mechanical property of CF/PEEK prepared by PBF were studied. The optimal CF for PBF of high strength CF/PEEK were obtained. The post‐processing method for improving the Z‐axis strength were proposed. CF/PEEK with comprehensive mechanical property was successfully prepared by PBF.

Comparison between CFR-PEEK and titanium plate for proximal humeral fracture: A meta-analysis.

The aim of the present meta-analysis was to compare the efficacy and safety of the carbon fiber-reinforced polyetheretherketone (CFR-PEEK) and titanium plate for the treatment of proximal humeral fractures (PHFs) from clinical comparative trials. A comprehensive search of English databases was carried out, such as PubMed, Web of Science, ScienceDirect, Springer and Cochrane Library databases. The RevMan version 5.1 software was applied for statistical analysis, and the mean difference (MD) and risk difference (RD) as the combined variables, and "95%" as the confidence interval (CIs). One randomized-controlled trial and five retrospective controlled studies including 282 PHFs were considered eligible and finally included. Meta-analysis demonstrated that there were significant differences in Constant score (CS) (MD=9.23; 95% CI: 5.02, 13.44; p<0.0001), anterior elevation (MD=18.83; 95% CI: 6.27, 31.38; p=0.003), lateral elevation (MD=18.42; 95% CI: 3.64, 33.19; p=0.01) and adduction (MD=3.53; 95% CI: 0.22, 6.84; p=0.04). No significant differences were observed regarding Constant score compared to the contralateral shoulder, Oxford Shoulder Score, internal rotation, external rotation, screw perforation and cutout, varus/valgus malalignment, humeral head collapse/necrosis, implant removal, and revision surgery between the two groups. Compared to titanium plate, CFR-PEEK plate showed better Constant score, anterior elevation, lateral elevation and adduction in treating PHFs. The complications are comparable to those achieved with conventional titanium plates.

CF/PEEK skins assembly by induction welding for thermoplastic composite sandwich panels

A method to assemble sandwich panels made of carbon fibre reinforced poly-ether-ether-ketone (CF/PEEK) facesheets and 3D-printed poly-ether-imide (PEI) honeycomb cores using induction welding is presented. Induction heating patterns inside CF/PEEK laminates of variable dimensions are first evaluated with a thermal camera and compared to a COMSOL Multiphysics model. Sandwich samples are then prepared by vacuum-assisted continuous induction welding under parameters selected from the modelling effort. Joining of sandwich panels made of CF/PEEK facesheets by induction welding under vacuum is demonstrated. Facesheets do not deconsolidate in the process and core crushing is avoided. Flatwise skin/core strength of the welded samples reaches up to 7 MPa, above reported performance for thermoset or thermoplastic composite sandwich panels.