Evonik is introducing a new carbon-fiber reinforced PEEK filament for use in 3D printed medical implants. This smart biomaterial can be processed in common extrusion-based 3D printing technologies such as fused filament fabrication (FFF). 
 
Dubbed VESTAKEEP iC4612 3DF and VESTAKEEP iC4620 3DF, the two available filaments feature 12% and 20% carbon fiber content, respectively. The two grades offer a choice of material depending on the required strength and flex properties of 3D printed implants such as bone plates and other reconstructive prostheses. 
 
Evonik’s VESTAKEEP iC4612 3DF and VESTAKEEP iC4620 3DF offer great benefits from the strength from the high carbon-fiber content, matched with the ductility of its PEEK component, according to Evonik. Additional product benefits include the ability to define the alignment of the carbon fibers during the 3D printing process, high bio-compatibility for metal allergy-patients, and the no x-rays artifacts.
 
Designing Smart Biomaterials for a Life Beyond Limits
“By introducing the world’s first carbon-fiber reinforced PEEK filament for long-term medical implants, we continue to design biomaterials that open up new possibilities in today’s medical technology for patient-specific treatment,” said Marc Knebel, head of Medical Systems at Evonik. “As experts with decades of experience in polymer chemistry, we combine a unique set of competencies in materials science, manufacturing technologies and regulatory expertise to customers to accelerate time-to-market of new medical technologies for people’s lives beyond limits.”
 
With a 1.75 mm diameter, VESTAKEEP iC4612 3DF and VESTAKEEP iC4620 3DF are supplied on 500g and 1,000g spools that can be used directly in standard FFF/FDM 3D printers for PEEK materials. The filament is subjected to strict quality management for medical materials.
 
“No other application field showcases more the advantages of 3D printing, such as individualization or design freedom, than medical technology,” Knebel stated. “In trauma applications, for instance, 3D printed solutions offer an enormous time advantage over traditionally manufactured medical devices. It is conceivable that patient-specific solutions can be manufactured within two or three days, significantly improving the recovery phase.”
 
Over the last five years, Evonik has been gradually developing new PEEK-based filaments for medical 3D printing applications and thus setting material quality standards in medical technology with additive manufacturing. The current portfolio includes different grades for long-term and short-term body contact applications. 
 
Long-term body contact applications:

• VESTAKEEP i4 3DF – Implant grade (long-term)
• VESTAKEEP i4 3DF-T – Test and development grade
• VESTAKEEP iC4800 3DF – Osteoconductive implant grade
• VESTAKEEP iC4612 3DF – Carbon-fiber reinforced (12%) implant grade
• VESTAKEEP iC4620 3DF – Carbon-fiber reinforced (20%) implant grade

 
Short-term body contact applications: VESTAKEEP Care M40 3DF – Medical care grade. 
 
Evonik manufactures smart biomaterials for additive manufacturing technologies. The specialty chemicals company offers an extensive portfolio of 3D-printable biomaterials for medical technology that can be used to manufacture medical device parts designed for temporary and permanent body contact. In addition to PEEK-based filaments of the VESTAKEEP brand, the portfolio includes the RESOMER line of bioresorbable filaments, powders, and granules for implantable medical devices.