Numerical and experimental investigation of a 3D-printed PCU patient-specific cranial implant

Arburg plastic freeforming (APF) technology allows for fabricating patient-specific implants (PSIs) in a hospital environment using medical-grade thermoplastic polymers. Among these materials, poly(carbonate-urethane) (PCU) is of great relevance since it is characterised by excellent biocompatibility. This study explores the opportunity to realise a patient-specific cranial plate via APF. First, a Finite Element model (FEM) of the implant under compressive loads is developed and validated using a quasi-isotropic material. Then, this model is used for Finite Element Analysis (FEA) considering Technical Datasheet (TDS) material properties and those measured on 3D-printed specimens, by Three-Point Bending (TPB) tests. Finally, a PCU PSI is fabricated through APF and tested under static loads to validate the consistency of the numerical results. Considering TDS properties, the FEA results indicate that PCU can be used for the manufacturing of this device. Nonetheless, the TPB tests show that the material suffers from a loss of mechanical properties. Using these properties, the displacements calculated via FEA exceed the admissible values for the application. A further decrease in stiffness is observed in the manufactured plate. Overall, findings suggest that PCU can be a viable material to be printed by APF technology for fabricating craniofacial PSIs, with the advantage of minor stress concentration in critical points of the implant if compared with polyetheretheretherketone (PEEK). However, further studies are necessary to effectively represent the effects of 3D printing in the FEMs used for structural validation and design optimisation