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<p>The fabrication of implantable medical devices through additive manufacturing presents a significant opportunity for future medicine. Developing biodegradable and implantable polymer and composite materials holds promise for creating bone substitutes to facilitate bone reconstruction. One such material currently under development is a dense composite of polylactic acid (PLA) with bio-glass (BG) filler. However, the coupling of PLA and bio-glass in this composite makes it highly sensitive to temperature and water adsorption, accelerating its hydrolytic degradation. Shaping this composite at high temperatures using injection molding or additive manufacturing processes is, therefore, particularly complex. The aim of this study is to print dense and strong composites of P(L,DL)LA with 5 wt.% bio-glass filler with a technology that combines injection molding and inkjet printing processes (Arburg Plastic Freeforming, APF). The printability of this composite with APF was demonstrated. Printing parameters were optimized to balance fluidification and thermal degradation to manufacture dense and strong parts (88 ± 1&#xa0;MPa of compressive yield strength). However, issues of printing reproducibility and material degradation were observed. The severe thermo-mechanical degradation of the polymer matrix during the process, catalysed by the bio-glass filler, is further exacerbated by moisture absorption during printing and elevated shear stresses inherent to the injection process. These challenges may be attributed to various factors, including moisture uptake, thermomechanical degradation of the material, but also fast degradation of the printing nozzle. Strategies to modify the technology itself, or the material, are proposed.</p>

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Addressing challenges in additive manufacturing of polylactic acid -P(L,DL)LA- and bio-glass composites for implantable medical devices

  • 期刊论文

  • 发表日期：

    2025年3月25日

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  • Erica Roitero,
  • Julien Le Boterff,
  • Jérôme Chevalier,
  • Christophe Marquette,
  • Jean-Marc Chenal,
  • Edwin-Joffrey Coutial

摘要

The fabrication of implantable medical devices through additive manufacturing presents a significant opportunity for future medicine. Developing biodegradable and implantable polymer and composite materials holds promise for creating bone substitutes to facilitate bone reconstruction. One such material currently under development is a dense composite of polylactic acid (PLA) with bio-glass (BG) filler. However, the coupling of PLA and bio-glass in this composite makes it highly sensitive to temperature and water adsorption, accelerating its hydrolytic degradation. Shaping this composite at high temperatures using injection molding or additive manufacturing processes is, therefore, particularly complex. The aim of this study is to print dense and strong composites of P(L,DL)LA with 5 wt.% bio-glass filler with a technology that combines injection molding and inkjet printing processes (Arburg Plastic Freeforming, APF). The printability of this composite with APF was demonstrated. Printing parameters were optimized to balance fluidification and thermal degradation to manufacture dense and strong parts (88 ± 1 MPa of compressive yield strength). However, issues of printing reproducibility and material degradation were observed. The severe thermo-mechanical degradation of the polymer matrix during the process, catalysed by the bio-glass filler, is further exacerbated by moisture absorption during printing and elevated shear stresses inherent to the injection process. These challenges may be attributed to various factors, including moisture uptake, thermomechanical degradation of the material, but also fast degradation of the printing nozzle. Strategies to modify the technology itself, or the material, are proposed.