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<p>In this work, a series of 3D-printed orthopedic footpad composite samples were fabricated using thermoplastic polyurethane (TPU) and polylactic acid (PLA) as supporting structures, infused with biopolymeric fillers including polycaprolactone (PCL), sodium alginate, and natural mastic resin. Twelve different formulations were prepared and systematically assessed through structural (FTIR, SEM), physicochemical (wettability, absorbency), biological (antifungal and antibacterial activity and cytotoxicity), and mechanical (tensile and compressive strength) tests to estimate their performance under simulated physiological conditions. Among all samples, TPU-based composite filled with 90% PCL and 10% sodium alginate (TPA) exhibited superior multi-functional performance. FTIR analysis confirmed successful physical compatibility between TPU and PLA with hydrophilic additives without chemical bonding. FESEM images revealed a well-integrated, homogeneous microstructure with minimized voids and enhanced surface coherence for both groups. Wettability measurements showed lowest contact angle (41.06°) presented a significant increase in hydrophilicity for PCL-based composites e.g., TPA and PPM (PLA filled with 90% PCL + 10% mastic), resulting in high hydrophilicity, which correlated with its maximum sweat absorbency up to 63.58% in TPA and 56.50% in PPM. Furthermore, TPA demonstrated effective antifungal activity against <i>C. albicans</i> (13&#xa0;mm inhibition zone) and <i>C. parapsilosis</i> (10&#xa0;mm). In terms of mechanical behavior, PLA-based samples had higher tensile strength (up to 28.79&#xa0;MPa for sample P) had higher compressive strength (up to 40.71&#xa0;MPa), while TPU-based samples presented superior elasticity (elongation &gt; 250%) and impact-absorbing capabilities. Statistical analysis confirmed highly significant differences (<i>p</i> &lt; 0.01) among all formulations in terms of wettability, absorbency, tensile strength, compressive strength, and cell viability. Cytotoxicity predictions revealed that PCL/alginate-rich composites (TPA, PA, PPA) achieved the highest viability (≈ 88–90%), whereas resin-rich samples (TM, PM) fell near the lower viability range due to bioactive compound release. Overall, among all formulations, TPA and PPA demonstrated the most balanced and optimal combination of structural integrity, hydrophilicity, mechanical robustness, antimicrobial activity, and cytocompatibility, making them the strongest candidates for next-generation biomedical and orthopedic footpads.</p>

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Preparation and characterization of 3D-printed bio-composite footpads using TPU and PLA structures with polymeric infiltration

  • 期刊论文

  • 发表日期：

    2026年2月5日

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  • Fatimah J. Al-Hasani,
  • Zainab Jawad Kadhim,
  • Emad S. Al-hassani

摘要

In this work, a series of 3D-printed orthopedic footpad composite samples were fabricated using thermoplastic polyurethane (TPU) and polylactic acid (PLA) as supporting structures, infused with biopolymeric fillers including polycaprolactone (PCL), sodium alginate, and natural mastic resin. Twelve different formulations were prepared and systematically assessed through structural (FTIR, SEM), physicochemical (wettability, absorbency), biological (antifungal and antibacterial activity and cytotoxicity), and mechanical (tensile and compressive strength) tests to estimate their performance under simulated physiological conditions. Among all samples, TPU-based composite filled with 90% PCL and 10% sodium alginate (TPA) exhibited superior multi-functional performance. FTIR analysis confirmed successful physical compatibility between TPU and PLA with hydrophilic additives without chemical bonding. FESEM images revealed a well-integrated, homogeneous microstructure with minimized voids and enhanced surface coherence for both groups. Wettability measurements showed lowest contact angle (41.06°) presented a significant increase in hydrophilicity for PCL-based composites e.g., TPA and PPM (PLA filled with 90% PCL + 10% mastic), resulting in high hydrophilicity, which correlated with its maximum sweat absorbency up to 63.58% in TPA and 56.50% in PPM. Furthermore, TPA demonstrated effective antifungal activity against C. albicans (13 mm inhibition zone) and C. parapsilosis (10 mm). In terms of mechanical behavior, PLA-based samples had higher tensile strength (up to 28.79 MPa for sample P) had higher compressive strength (up to 40.71 MPa), while TPU-based samples presented superior elasticity (elongation > 250%) and impact-absorbing capabilities. Statistical analysis confirmed highly significant differences (p < 0.01) among all formulations in terms of wettability, absorbency, tensile strength, compressive strength, and cell viability. Cytotoxicity predictions revealed that PCL/alginate-rich composites (TPA, PA, PPA) achieved the highest viability (≈ 88–90%), whereas resin-rich samples (TM, PM) fell near the lower viability range due to bioactive compound release. Overall, among all formulations, TPA and PPA demonstrated the most balanced and optimal combination of structural integrity, hydrophilicity, mechanical robustness, antimicrobial activity, and cytocompatibility, making them the strongest candidates for next-generation biomedical and orthopedic footpads.