Surface Modification by Using Additive Manufacturing and Cold Spray for Peek Spinal Cage Fabrication

The purpose of this project is to produce polyetheretherketone (PEEK) spinal cages by usingadditive manufacturing and cold spraying for surface modification. This study will propose a novelapproach to produce PEEK spinal cages with high porosity and biological activity. Thehigh-porosity cages will be fabricated based on the fused deposition modeling (FDM) technology.The bioactive material powders will be sprayed on the surface of molten PEEK by the cold sprayingtechnology during the FDM process. Since the molten PEEK is subsequently cooled to a solid state,the particles will be firmly embedded into the PEEK surface with high adhesive strength. This canimprove the biological activity of PEEK, and it will not reduce the mechanical properties of theoriginal PEEK. In addition, there is no shedding problem compared with general surface coatings.The project is planned for a two-year period, with the first year focusing on the implement of coldspray technology on the FDM process. A variety of test specimens will be made and tested forverifying the proposed method. The second year was to integrate FDM and cold spraying into anautomated process that allowed bioactive particles to be sprayed in place during the FDM process.This project would develop a new and clinically effective spinal cage for the surgeon to use.