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Transfer film effects induced by 3D-printed polyether-ether-ketone with excellent tribological properties for joint prosthesis

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Abstract

Based on the building principle of additive manufacturing, printing orientation mainly determines the tribological properties of joint prostheses. In this study, we created a polyether-ether-ketone (PEEK) joint prosthesis using fused filament fabrication and investigated the effects of printing orientation on its tribological properties using a pin-on-plate tribometer in 25% newborn calf serum. An ultrahigh molecular weight polyethylene transfer film is formed on the surface of PEEK due to the mechanical capture of wear debris by the 3D-printed groove morphology, which is significantly impacted by the printing orientation of PEEK. When the printing orientation was parallel to the sliding direction of friction, the number and size of the transfer film increased due to higher steady stress. This transfer film protected the matrix and reduced the friction coefficient and wear rate of friction pairs by 39.13% and 74.33%, respectively. Furthermore, our findings provide a novel perspective regarding the role of printing orientation in designing knee prostheses, facilitating its practical applications.

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Acknowledgements

This study was supported by the following funds: (1) National Key R&D Program of China (No. 2018YFE0207900); (2) Program for Innovation Team of Shaanxi Province (No. 2023-CX-TD-17); (3) Program of the National Natural Science Foundation of China (No. 51835010); (4) Key R&D Program of Guangdong Province (No. 2018B090906001); (5) Natural Science Basic Research Program of Shaanxi Province (No. 2022JQ-378); (6) China Postdoctoral Science Foundation (No. 2020M683458); (7) Fundamental Research Funds for the Central Universities; (8) Youth Innovation Team of Shaanxi Universities.

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Authors and Affiliations

  1. State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, **’an Jiaotong University, **’an, 710054, China

    Yang Li, Jibao Zheng, Changning Sun & Dichen Li

  2. National Medical Products Administration (NMPA) Key Laboratory for Research and Evaluation of Additive Manufacturing Medical Devices, **’an Jiaotong University, **’an, 710054, China

    Yang Li, Jibao Zheng, Changning Sun & Dichen Li

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Contributions

YL contributed to conceptualization, methodology, data curation and writing-original draft; JBZ contributed to conceptualization, methodology and investigation; CNS contributed to conceptualization, validation and formal analysis; DCL contributed to funding acquisition and administration, and reviewed the initial versions of the manuscript. All authors have read and approved the final manuscript.

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Correspondence to Dichen Li.

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Li, Y., Zheng, J., Sun, C. et al. Transfer film effects induced by 3D-printed polyether-ether-ketone with excellent tribological properties for joint prosthesis. Bio-des. Manuf. 7, 43–56 (2024). https://doi.org/10.1007/s42242-023-00258-y

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