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<p>In the previous two decades, several studies have testified using 3D-printed bio-compatible/ bio-degradable polymers in orthopaedic applications. However, little has been reported on selecting fused filament fabrication (FFF) processing parameters for sensor fabrication required in comminuted fracture monitoring. This study presents a multifactor optimization for selecting FFF parameters to improve the mechanical and sensing capabilities of polylactic acid (PLA)-hydroxyapatite (HAp)-chitosan (CS) (98%)-BaTiO<sub>3</sub> (2%) -based sensors for comminuted fracture monitoring. A general linear model (GLM) was applied to optimize tensile stiffness (TS) and bending stiffness (BS) for comminuted fracture monitoring in the tibia/femur bones of canines. The suggested optimal settings are 100% infill density (ID), 210&#xa0;°C nozzle temperature (NT), and honeycomb infill pattern (IP), yielding a composite desirability of 0.92, with targeted values of 7643.31 kN/m (TS) and 23.0 kN/m (BS). Experimental validation resulted in 7,565.21 kN/m TS and 60 kN/m BS. Morphological analysis showed 13.90% porosity (in flexural samples) and 7.29% (in tensile samples). The dielectric analysis confirmed a dielectric constant (ε′) of 2.62 and piezoelectric coefficients (D<sub>33</sub>) of 199 pC/N (in flexural samples) and 195 pC/N (in tensile samples). The thermal analysis demonstrated stability up to 250&#xa0;°C, and the in-vitro corrosion rate was 5.97 × 10⁷ mm/year. These findings confirm the PLA composite’s suitability for real-time sensing in canine orthopaedic implants. The outcomes were braced by the morphological analysis (scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), percentage of porosity), bond characteristics (Fourier transformation infrared spectroscopy (FTIR), and thermal analysis (differential scanning calorimetry (DSC), thermogravimetric analysis (TGA)).</p>

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On Fused Filament Fabrication of Polylactic Acid Composite for the Fabrication of Comminuted Fracture Monitoring Sensors

  • 期刊论文

  • 发表日期：

    2026年2月14日

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  • Gurwinder Singh,
  • Minhaz Husain,
  • Rupinder Singh,
  • Amrinder Pal Singh

摘要

In the previous two decades, several studies have testified using 3D-printed bio-compatible/ bio-degradable polymers in orthopaedic applications. However, little has been reported on selecting fused filament fabrication (FFF) processing parameters for sensor fabrication required in comminuted fracture monitoring. This study presents a multifactor optimization for selecting FFF parameters to improve the mechanical and sensing capabilities of polylactic acid (PLA)-hydroxyapatite (HAp)-chitosan (CS) (98%)-BaTiO3 (2%) -based sensors for comminuted fracture monitoring. A general linear model (GLM) was applied to optimize tensile stiffness (TS) and bending stiffness (BS) for comminuted fracture monitoring in the tibia/femur bones of canines. The suggested optimal settings are 100% infill density (ID), 210 °C nozzle temperature (NT), and honeycomb infill pattern (IP), yielding a composite desirability of 0.92, with targeted values of 7643.31 kN/m (TS) and 23.0 kN/m (BS). Experimental validation resulted in 7,565.21 kN/m TS and 60 kN/m BS. Morphological analysis showed 13.90% porosity (in flexural samples) and 7.29% (in tensile samples). The dielectric analysis confirmed a dielectric constant (ε′) of 2.62 and piezoelectric coefficients (D33) of 199 pC/N (in flexural samples) and 195 pC/N (in tensile samples). The thermal analysis demonstrated stability up to 250 °C, and the in-vitro corrosion rate was 5.97 × 10⁷ mm/year. These findings confirm the PLA composite’s suitability for real-time sensing in canine orthopaedic implants. The outcomes were braced by the morphological analysis (scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), percentage of porosity), bond characteristics (Fourier transformation infrared spectroscopy (FTIR), and thermal analysis (differential scanning calorimetry (DSC), thermogravimetric analysis (TGA)).