Composite based on polyetheretherketone reinforced with carbon fibres, an alternative to conventional materials for femoral implant: Manufacturing process and resulting structural behaviour

Composite stems obtained by injection moulding of polyetheretherketone reinforced with carbon fibres (CF/PEEK) can concurrence metallic ones in total hip replacement. By the combination of process simulations and structural analysis, different compositions of CF/PEEK and injection conditions are explored. The resulting implants are compared to the bone alone and the bone-implant system based on conventional metallic materials, under walking load. Comparisons are done through four objective criteria: stress shielding, stress deficiency, debonding and global deformation. CF/PEEK injected implant presents very good results.

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► We model a composite (CF/PEEK) hip implant obtained by injection moulding.
► Composite stems are compared to classical metallic stems (Stainless Steel, Titanium alloy, Co–Cr alloy).
► The study is based on walking loading.
► For the comparisons, four criteria are used: stress shielding, bone resorption, risk of failure, deflection.
► A program has been developed to account manufacturing process in functional behaviour.