390 Assessing Biocompatibility & Mechanical Testing of 3D-Printed PEEK Versus Milled PEEK in Maxillofacial Surgical Applications

Abstract Aim PEEK (poly-ether-ether-ketone) is an innovative thermoplastic polymeric biomaterial used in Maxillofacial Surgery. As opposed to metallic implants, implants can be 3D-printed specifically for patients and do not suffer stress shielding effects- a major cause of implant failure. This investigation aimed compare mechanical integrity biocompatibility modern against traditionally produced Milled-PEEK biomaterials e.g., Titanium. Method Fused-deposition-modelling non-CNC Milling were produce ASTM/ISO-designed samples. Samples designed using the Apium P155 FDM-3D-printer, Fusion 360 Simplify3D software. Fracture Toughness KIc, Tensile Strength, Vickers micro-hardness 3-point flexural strength tests performed. Cell adhesion on sandblasted was evaluated by culturing primary human endothelial cells osteoblasts (HUVEC, HOBS) evaluating cell growth. Results Milled had higher tensile (p=0.022), (p<0.0001) fracture toughness (p=0.003) than FDM-printed PEEK. However, demonstrated microhardness (p=0.014). Both FDM showed values normal ranges cortical bone, close alternative bone-replacement biomaterials. HOBS HUVEC strong with >95% viability. Conclusions 3D-printing emerging technology advantages over milling production. Nonetheless, this manufacturing modality may devices lower resistance parameters compared milled PEEK, but compatible natural bone. Sandblasting create uniform micro-rough surfaces potentially enhancing osseointegration host tissue.