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Replication of Overmolded Orthopedic Implants with a Functionalized Thin Layer of Biodegradable Polymer

Elkaseer, Ahmed 1; Mueller, Tobias ORCID iD icon 1; Azcarate, Sabino; Philipp-Pichler, Martin; Wilfinger, Thomas; Wittner, Wolfgang; Prantl, Manfred; Sampaio, Daniel; Hagenmeyer, Veit 1; Scholz, Steffen ORCID iD icon 1
1 Institut für Automation und angewandte Informatik (IAI), Karlsruher Institut für Technologie (KIT)


The present paper reports on the development of a biodegradable overmolded orthopedic implant: a metal bone fixing screw, which has been overmolded with a functionalized thin layer of biodegradable polymer to enhance cell adhesion during the healing process. The main challenges were to integrate precise, high-throughput and repeatable solutions to achieve a thin, defect-free structured polymer layer and to ensure a high and consistent implant quality. The work carried out entailed determining proper materials (Purasorb PDLG 5010) for the biodegradable overmolding layer and its economical substitute (NaKu PLA 100HF) to be used during initial tool and process development, designing the surface structure of the overmolded polymer layer, development of injection molding tools, as well as feeding and handling procedures. The injection overmolding process of Purasorb PDLG 5010 polymer was controlled, and the process parameters were optimized. In particular, the dominant process parameters for the overmolding, namely injection pressure, barrel temperature and mold temperature, were experimentally examined using a circumscribed three-factor central composite design and two quality marks; overmolding roughness and mass of polymer. ... mehr

Verlagsausgabe §
DOI: 10.5445/IR/1000084123
Veröffentlicht am 02.07.2018
DOI: 10.3390/polym10070707
Zitationen: 9
Web of Science
Zitationen: 6
Zitationen: 11
Cover der Publikation
Zugehörige Institution(en) am KIT Institut für Automation und angewandte Informatik (IAI)
Publikationstyp Zeitschriftenaufsatz
Publikationsjahr 2018
Sprache Englisch
Identifikator ISSN: 2073-4360
KITopen-ID: 1000084123
HGF-Programm 43.22.03 (POF III, LK 01) Printed Materials and Systems
Erschienen in Polymers
Verlag MDPI
Band 10
Heft 7
Seiten Article: 707
Bemerkung zur Veröffentlichung Gefördert durch den KIT-Publikationsfonds
Vorab online veröffentlicht am 26.06.2018
Schlagwörter orthopedic implants; biodegradable polymer; functionalized surface; micro injection molding; process optimization
Nachgewiesen in Dimensions
Web of Science
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