ELEMENTS Interview | Quantum leap for spinal implants from the 3D printer

When a patient receives an implant, its material plays a key role in recovery. Vestakeep PEEK from Evonik is popular in the market for medical devices. This is due to the many advantages of the material. But:

“The history of PEEK was a little bit plagued with an Achilles heel of being a very hydrophobic material. Despite having ideal radiolucency and mechanical properties for musculoskeletal and spinal implants, the ability for bone to bond to that was a bit limited.”

... explains Dr. Erik Erbe, Chief Scientific Officer of Curiteva, the limitations so far. In cooperation with Evonik, the US company has found a solution: they invented the world's first 3D-printed spinal implants for commercial use. The implants are based on a variant of the thermoplastic polyether ether ketone, or PEEK for short.

“We were the first cleared implant by FDA and the machine that we built internally, was the first machine that was used to print 3D musculoskeletal implants.”

A real break-through - thanks to the vision of an ambitious inventor: Todd Reith. Years ago he already foresaw that the properties of PEEK combined with the possibilities of 3D printing had the potential to revolutionize orthopedics. Experts from Evonik shared his conviction. Together with Reith, they achieved what previously seemed almost impossible within three years: to develop a 3D printable filament for medical applications made from VESTAKEEP granules - VESTAKEEP i4 3DF. Todd Reith on the collaboration:

“Evonik helped Curitiva get our technology to market by being an incredible partner. They've been critical in providing technical assistance and scientific advisory and also guidance through the FDA process when we went through our clearance.”

Thanks to Curiteva's 3D printing process, it is now possible to print a fully porous spinal implant using Evonik's filament. It mimics the fine structure of the bone and can therefore bond better with it. Plus, the implants are even stronger than those made of conventionally manufactured PEEK.

The practical test has been successfully completed: in April 2023, surgeons in the USA used one of the "inspire" spinal implants made from the VESTAKEEP i4 3DF PEEK filament for the first time. An important step - but not the last: Evonik is now focusing on exploiting the commercial potential of the material on the market. In the future implants for feet, hands, the head or face can be created with 3D-printed PEEK - custom-made for each individual patient.