Strategy for Controlling the Properties of Bioactive Poly-Ether-Ether-Ketone/Hydroxyapatite Composites for Bone Tissue Engineering Scaffolds

[Image: see text] A strategy for the preparation of bioactive poly-ether-ether-ketone/hydroxyapatite (PEEK/HA) composites was proposed in this study with the aim of controlling the biological and mechanical properties of different parts of the composites. The strategy integrated solvent-based extrusion freeforming 3D printing technology in order to print high-resolution HA scaffolds and compression molding processes for the production of bioactive PEEK/HA composites. To this end, an optimized model, established using response surface methodology, was employed to optimize the extrusion process parameters on the basis of accurate characterization of the extrusion pressure, and the effects of the filament/pore sizes on the PEEK infiltration depth into the HA scaffold were investigated. The results of scanning electron microscopy and computed tomography analyses revealed that the PEEK/HA composites exhibited a uniform microstructure and a good interface between the HA filaments and the PEEK matrix following the optimization of the process parameters. The HA scaffolds were fully infiltrated by PEEK in both vertical and lateral directions with an infiltration depth of 3 mm while maintaining the HA network structure and uniformity. The biological and mechanical performance test results validated that the PEEK/HA composites possessed excellent biocompatibility as well as yields and compressive strengths within the range of human cortical bone suitable for load-bearing applications.