Advanced MaterialsMedical Additive ManufacturingOrthopedic Implants

FossiLabs presents 3D printed PEEK bone-like scaffolding structures

First-of-its-kind 3D printed PEEK porous medical implants with advanced hydrophilicty

FossiLabs, LLC, a startup company focused on engineering porous bone-like structures in polyether ether ketone (PEEK), launched the first-ever fused filament fabrication (FFF) 3D printed ‘fully’ porous PEEK bone- like structures within implantable devices. FossiLabs novel offering now makes it possible to 3D print solid or defined porous structures anywhere within the 3D space. Prior to this development, all other product offerings have only had surface porosity or windows within defined layers. The only viable alternative for 3D printing implantable, medical-grade PEEK is via SLS technology (EOS), with significantly higher costs.

FossilabsFossiLabs developed proprietary hardware and software to make it possible to easily identify solid and controlled bone-like macroporosity regions within existing client models. Primarily for spacers and cages for the spine, desired bone growth areas can be defined, and 3D printed in PEEK. The implants also use increased surface area and hydroxyapatite (HA) nanocoating surfaces to provide unparalleled hydrophilicity and faster osseointegration.

“Using 3D printing technology makes it possible to create a porous structure that would not be possible using traditional methods. The increased surface area and the full porosity encourage new bone on-growth and in-growth of the implant, leading to greater integration strength. Add hydroxyapatite (HA) nanocoating, now you have something unmatched in the industry,” said Todd Reith, Founder/President at FossiLabs.

The implants are based on Evonik’s Vestakeep PEEK material, a polymer monofilament that was designed specifically for the fused filament fabrication (FFF) process. The Evonik range includes implant-grade VESTAKEEP 3DF Filament PEEK filament, based on VESTAKEEP PEEK i4G, and VESTAKEEP 3DF-T Filament, a technical grade of VESTAKEEP 3DF Filament for testing and early evaluation of printing behavior and results. VESTAKEEP i4 G exhibits high biocompatibility, biostability, and x-ray transparency.

With a proven process and proof of concept, FossiLabs is now seeking medical device companies to license its technology to enhance their existing static product lines and develop exclusive new high-performance products.


Davide Sher

Since 2002, I have built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, I spent 12 years in the United States, where I received my Bachelor of Arts undergraduate degree. As a journalist covering the tech industry - especially the videogame industry - for over 10 years, I began covering the AM industry specifically in 2013, as blogger. In 2016 I co-founded London-based 3D Printing Business Media Ltd. (now 3dpbm) which operates in marketing, editorial, and market analysis & consultancy services for the additive manufacturing industry. 3dpbm publishes 3D Printing Business Directory, the largest global directory of companies related to 3DP, and leading news and insights websites 3D Printing Media Network and Replicatore. I am also a Senior Analyst for leading US-based firm SmarTech Analysis focusing on the additive manufacturing industry and relative vertical markets.

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