Personalised 3D-printed bioactive peek bone plate scaffold for treating femoral defects.

Fractures affect millions of individuals worldwide, particularly those with osteoporosis, and often require rigid fixation for proper healing. Although traditional metal bone plates are effective, they are limited by their stiffness and inability to conform precisely to anatomical structures, leading to complications such as stress shielding and delayed healing. In this study, we utilized computer-aided design (CAD) combined with reverse engineering to develop a 3D bone plate scaffold model that perfectly matches the contours of the rabbit femur. Additionally, we employed fused deposition modeling (FDM) 3D printing to fabricate a customized polyetheretherketone (PEEK) bone plate scaffold based on the model, designed to match individual bone structures and reduce rigidity-related issues. To enhance the bioactivity of the PEEK scaffold surface, we applied plasma spraying technology to coat it with bioactive materials, including nanohydroxyapatite (HA), tantalum (Ta), and titanium (Ti). The results showed that the HA coating contained 48.06% calcium (Ca) and 16.47% phosphorus (P) and the Ti coating contained 82.32% Ti. In vitro studies showed that the bioactive scaffold effectively promoted the proliferation and differentiation of osteogenic mesenchymal stem cells, with a cell survival rate greater than 93.86%. Moreover, in vivo results from the rabbit femoral defect model showed that the bioactive scaffolds significantly accelerated bone tissue healing, with HA-coated PEEK scaffolds exhibiting exceptional bone regeneration potential. This study proposes a comprehensive strategy for customizing bone plate scaffolds, which holds significant promise for personalized precision medicine.