个性化聚醚醚酮植入物的制造工艺研究

Manufacturing Process of Personalized Polyetheretherketone Implants

为了解决个性化假体数控加工材料浪费严重、加工成本高、异形薄壁件加工困难,以及增材制造力学性能不足的难题,提出了一种利用光固化3D打印技术制造个性化聚醚醚酮(poly-ether-ether-ketone,PEEK)假体的耐高温树脂注塑模具,并进一步通过注塑工艺获得高强度个性化假体的方案。该方案充分地结合了3D打印技术和传统注塑技术的优势,即利用3D打印技术实现复杂的结构形状,利用传统注塑技术实现优异的综合力学性能。研究了在模芯设计过程中分型面的设计原则、模芯合模固定方式的选择原则以及模芯是否填充材料的原则。利用该方案制造了个性化PEEK颅骨和下颌骨假体,并对注塑件进行结晶度测试、组织观察。结果显示,PEEK注塑件的结晶度为30.82%,注塑件组织致密,无孔隙和缺损。因此,采用3D打印和注塑相结合的方案制造具有综合力学性能的个性化PEEK植入物是可行的,对个性化PEEK植入物在临床的广泛应用具有一定的参考作用。

To solve the problems,including serious material waste in CNC machining,high processing cost,difficult processing of thin-wall shaped parts,and insufficient mechanical properties of additive manufacturing,a 3D printing stereolithography is used to manufacture high-temperature resistance resin injection mold for personalized polyetheretherketone(PEEK)prosthesis,and a high strength personalized prosthesis is then obtained by injection molding process.The program fully combines the advantages of 3D printing technology with traditional injection molding technology,namely 3D printing technology realizes complex structural shapes,and traditional injection molding technology achieves excellent comprehensive mechanical properties.In the mold core design process the design principle of the parting surface,the selection principle of the mold core fixing method and the principle of whether the core is filled with materials are considered.Personalized PEEK skull and mandibular prosthesis are fabricated by using this protocol,and crystallinity test and tissue observation of the injection molded parts are carried out.The results show that the crystallinity of PEEK injection molded parts reaches 30.82%,and the injection molded parts are densely organized without porosity and defects.Therefore,it is feasible to manufacture personalized PEEK implants with comprehensive mechanical properties by combining 3D printing technology with injection molding technology,especially for the applications of personalized PEEK implants to clinical cases.