Application-matched point-of-care 3D printing of functionalized polyetheretherketone (PEEK) composites for patient-specific craniomaxillofacial implants.

Jokin Zubizarreta Oteiza, Yannick Krieger, Daniel Seiler, Florian M Thieringer, Neha Sharma

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Article in 3D printing in medicine, 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.

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5 · Who and what money

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5 authors.

Jokin Zubizarreta OteizaMedical Additive Manufacturing Research Group (Swiss MAM), Department of Biomedical Engineering, University of Basel, Hegenheimermattweg 167b, Allschwil, 4123, Switzerland.

Yannick Krieger3DSystems, Flößergasse 4, 81369, Munich, Germany.

Daniel SeilerInstitute for Medical Engineering and Medical Informatics, University of Applied Sciences and Arts Northwestern Switzerland, Hofackerstrasse 30, Muttenz, 4132, Switzerland.

Florian M ThieringerMedical Additive Manufacturing Research Group (Swiss MAM), Department of Biomedical Engineering, University of Basel, Hegenheimermattweg 167b, Allschwil, 4123, Switzerland.

Neha SharmaMedical Additive Manufacturing Research Group (Swiss MAM), Department of Biomedical Engineering, University of Basel, Hegenheimermattweg 167b, Allschwil, 4123, Switzerland. neha.sharma@unibas.ch.

Funding

No grant is acknowledged in the PubMed record.

6 · The paper itself

Abstract

backgroundNative polyetheretherketone (PEEK) exhibits limitations in mechanical strength, radiographic visibility, and bioactivity for craniomaxillofacial (CMF) applications. This proof-of-concept study establishes the feasibility of point-of-care (POC) manufacturing for three functionalized PEEK composites for patient-specific CMF implants using a high-temperature material extrusion (MEX) system, with application-specific material selection to overcome these limitations.

methodsCarbon fiber-reinforced PEEK (CFR-PEEK), barium sulfate-filled PEEK (BaSO₄-PEEK), and biphasic calcium phosphate-filled PEEK (BCP-PEEK) were fabricated into patient-specific mandibular reconstruction plates, orbital floor implants, and chin augmentation implants, respectively. Manufacturing success rates, dimensional accuracy via root mean square (RMS) deviation analysis, post-sterilization dimensional stability, and layer adhesion quality were evaluated.

resultsFabrication success rates of 100% (CFR-PEEK), 100% (BaSO₄-PEEK), and 85.7% (BCP-PEEK) were achieved. Dimensional accuracy analysis revealed RMS deviations of 0.16-0.29 mm between 3D-printed implants and original designs, within clinically acceptable ranges. Post-sterilization dimensional changes were minimal (RMS 0.05-0.07 mm). Complete layer adhesion was demonstrated across all materials, with no delamination or cracking observed.

conclusionThese findings establish the manufacturing viability of POC fabrication of application-matched PEEK composites for patient-specific CMF implants, enhancing mechanical, radiographic, and bioactive properties whilst maintaining geometric customization.

Indexed as

3D printingAdditive manufacturingBarium sulfateBioactive polymersBiphasic calcium phosphateCarbon fiber reinforcementPoint of careRadiopaque polymersThermoplastic composites

Identifiers

PMID42340553

DOI10.1186/s41205-026-00331-z

PMCPMC13295568

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