FossiLabs presents 3D printed PEEK bone-like scaffolding structures

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.

FossiLabs 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.