Innovative Biomechanical Design and Performance of Carbon Fiber‐Thermoplastic Implants via Additive Manufacturing

ABSTRACT This study explores the potential of 3D‐printed carbon fiber‐reinforced thermoplastic composites, specifically Nylon and PEEK, as advanced materials for medical implants. Fabricated using fused filament fabrication (FFF), these implants were evaluated against conventional Ti‐6AL‐4V titanium alloy counterparts through a combination of experimental analysis and finite element method (FEM) simulations. The novel designs of discontinuous carbon fiber‐PEEK and continuous carbon fiber‐Nylon composites exhibited enhanced performance, reducing screw pull‐out force by nearly 50% relative to Ti‐6AL‐4V. Furthermore, the thermoplastic composites demonstrated significantly higher bio‐elastic coupling strain energy density (SED), indicating superior capacity to promote bone healing and callus formation. A comprehensive multi‐criteria evaluation—including metrics on screw loosening, bone remodeling, and resorption—revealed that the 3D‐printed composites outperformed titanium by 33%–65%. These results provide design guidelines for FFF 3D‐printed composite implants, offering considerable promise as customizable and effective alternatives to conventional metal implants.