High-performance polymers such as Polyetheretherketone (PEEK), Polyetherketoneketone (PEKK), and Carbon-reinforced PEEK are transforming personalized implant technology in reconstructive surgery. These materials offer exceptional mechanical properties, including high strength, wear resistance, and biocompatibility, making them ideal alternatives to traditional metals in applications such as spinal, craniomaxillofacial, and orthopedic implants. Leveraging advancements in 3D printing, our research group focuses on the material extrusion-based production of personalized high-performance polymer implants. This technology enables the creation of implants precisely tailored to a patient’s anatomy, improving surgical outcomes by reducing recovery times and enhancing implant integration. The ability to produce these personalized implants on demand at the point of care further enhances their practicality and accessibility.

Our research aims to unlock the potential of high-performance composite materials and medical 3D printing technologies, culminating in load-bearing, patient-specific implants that surpass current metallic standards. Here, we explore the possibility of Carbon-reinforced PEEK, which combines the lightweight nature of high-performance polymers with the added strength of carbon fibers, making it suitable for load-bearing applications. By doing so, we aim to mitigate inherent concerns associated with traditional materials, such as stress shielding and post-implantation imaging artifacts.