3D printer creating a bone implant

3D Printing Bone Implants: A New Frontier in Biomedical Engineering

Nico Varela in Tech & Innovation September 2025 • 4 min read.

"Exploring the mechanical and morphological properties of Polyamide 12 composite for potential biomedical implants using injection molding and desktop 3D printing."

The field of bone regeneration has seen remarkable advancements, driven by the need to address bone loss resulting from traumatic injuries, non-traumatic events, and various medical conditions. Replacing lost bone substance is crucial for restoring function and improving patient quality of life. While materials like titanium, polymethyl methacrylate (PMMA), and polyetheretherketone (PEEK) have been widely used, a groundbreaking technology is emerging: 3D printing.

3D printing, also known as additive manufacturing, is rapidly transforming the landscape of biomedical implants. This innovative technique allows for the creation of customized implants tailored to a patient's specific anatomy, offering numerous advantages over conventional methods. These benefits include enhanced aesthetic outcomes, reduced surgical time, minimized blood loss, and a decreased risk of infection.

Traditionally, the high costs associated with 3D printing limited its accessibility to large corporations and specialized research institutions. However, the advent of desktop, open-source 3D printers has democratized this technology, making it available to a wider audience at affordable prices. One such technique, fused filament fabrication (FFF), derived from Fused Deposition Modeling (FDM), has gained prominence. While initially used for creating spare parts and consumer products, 3D printing is now making significant strides in healthcare.

What are the Benefits of Polyamide 12 Composite in 3D-Printed Bone Implants?

Researchers have focused on polyamide (PA), specifically Polyamide 12, due to its excellent biocompatibility with human tissue and favorable mechanical properties. To further enhance its biological and mechanical characteristics, researchers have incorporated zirconium dioxide (ZrO2) and hydroxyapatite (HA) as fillers. This composite material aims to mimic the natural properties of bone, promoting better integration and long-term performance.

A study published in the Jurnal Teknologi investigated the mechanical and morphological properties of Polyamide 12 composite prepared using both desktop 3D printing and conventional injection molding. The researchers aimed to evaluate the feasibility of using 3D printing to create customized bone implants with enhanced properties.

Material Preparation: Polyamide 12 was compounded with 20 wt% filler loading of zirconium dioxide (ZrO2) and hydroxyapatite (HA).
Filament Creation: The composite was then extruded into filaments with a diameter of 1.75±0.1 mm using a desktop filament extruder.
3D Printing Process: The filament was used in a desktop 3D printer (Makerbot 2X) to create tensile and impact specimens based on virtual 3D models designed in SolidWorks.
Injection Molding: For comparison, specimens were also prepared using injection molding.

The mechanical properties of the 3D-printed and injection-molded Polyamide 12 composites were then rigorously tested and compared. The results indicated that the 3D-printed composite exhibited lower mechanical properties than the injection-molded composite. This difference was attributed to the formation of porosity, laminate weakness, and lower pressure during the 3D printing process.

The Future of 3D Printing in Bone Implants

While the mechanical properties of the 3D-printed parts were lower than those of the injection-molded parts, the study highlighted the immense potential of 3D printing for creating customized 3D objects. This capability opens up exciting possibilities for biomedical applications, particularly in the design and fabrication of personalized bone implants. Further improvements in printing parameters, such as layer height, infill percentage, and printing speed, could lead to enhanced material properties and wider adoption of 3D printing in the biomedical field. As technology advances, 3D-printed bone implants hold the promise of transforming bone regeneration, offering tailored solutions that improve patient outcomes and revolutionize healthcare.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.11113/jt.v76.5717, Alternate LINK

Title: Mechanical And Morphological Properties Of Polyamide 12 Composite For Potential Biomedical Implant: Injection Molding And Desktop 3D Printer

Subject: General Engineering

Journal: Jurnal Teknologi

Publisher: Penerbit UTM Press

Authors: Tuan Noraihan Azila Tuan Rahim, Hazizan Md Akil, Abdul Manaf Abdullah, Dasmawati Mohamad, Zainul Ahmad Rajion

Published: 2015-10-01

Everything You Need To Know

What is Polyamide 12 and why is it significant in 3D-printed bone implants?

Polyamide 12 (PA12) is a specific type of polymer that has garnered significant attention in the biomedical field, particularly for 3D-printed bone implants. Its significance stems from its excellent biocompatibility with human tissue, meaning it's well-tolerated by the body and unlikely to cause adverse reactions. Furthermore, PA12 possesses favorable mechanical properties, providing a good balance of strength and flexibility, which is crucial for bone implant applications. These characteristics make Polyamide 12 a promising material for creating implants that can effectively integrate with the body and facilitate bone regeneration. The research involving PA12 often incorporates fillers like zirconium dioxide (ZrO2) and hydroxyapatite (HA) to further enhance its mechanical and biological properties.

How does 3D printing technology contribute to improved patient outcomes in bone implant procedures?

3D printing offers several key advantages that directly translate to improved patient outcomes in bone implant procedures. The technology allows for the creation of customized implants tailored to a patient's specific anatomy, which is a stark contrast to traditional methods. This customization ensures a more precise fit, leading to enhanced aesthetic outcomes and potentially better functional results. Moreover, 3D printing can reduce surgical time and minimize blood loss, making the procedure less invasive and reducing the risk of complications. A notable benefit is the decreased risk of infection, as the precise fit and design can lead to better integration with the surrounding tissue, and reduced need for extensive manipulation. These factors collectively contribute to faster recovery times and improved overall patient satisfaction.

What are the primary steps involved in creating 3D-printed bone implants using Polyamide 12 composite?

The process of creating 3D-printed bone implants using Polyamide 12 composite involves several key steps, each playing a crucial role in the final product's quality and effectiveness. Firstly, the Polyamide 12 is compounded with fillers like zirconium dioxide (ZrO2) and hydroxyapatite (HA) to enhance its biological and mechanical properties. Next, this composite material is extruded into filaments, typically with a specific diameter, suitable for 3D printing. These filaments serve as the raw material for the printing process. A desktop 3D printer, such as a Makerbot 2X, then utilizes these filaments to build the implant layer by layer, based on a virtual 3D model designed using software like SolidWorks. The precise parameters of the 3D printing process, including layer height, infill percentage, and printing speed, play a critical role in the final mechanical properties of the implant.

How do the mechanical properties of 3D-printed Polyamide 12 composites compare to those created through injection molding, and why?

Studies have shown that 3D-printed Polyamide 12 composites generally exhibit lower mechanical properties compared to those produced via injection molding. This difference can be attributed to several factors inherent in the 3D printing process. Specifically, the formation of porosity (tiny voids) within the 3D-printed material weakens its structure. Additionally, the layer-by-layer deposition in 3D printing can lead to laminate weakness, where the bonds between layers are not as strong as in a solid, molded part. Furthermore, the lower pressure applied during the 3D printing process, compared to the high-pressure molding process, also contributes to reduced mechanical strength. While 3D printing offers unique customization advantages, these limitations highlight the need for optimizing printing parameters to improve the mechanical properties of 3D-printed implants.

What is the future outlook for 3D-printed bone implants, and what advancements are expected?

The future of 3D-printed bone implants looks exceptionally promising, holding the potential to revolutionize bone regeneration and healthcare. As technology advances, several key improvements are anticipated. Researchers are focusing on refining printing parameters, such as layer height, infill percentage, and printing speed, to enhance the mechanical properties of the printed implants. Furthermore, there's a push towards developing new composite materials with improved biocompatibility, strength, and the ability to promote bone growth. The availability of open-source and desktop 3D printers has democratized the technology, making it accessible to a wider audience. These advancements are expected to lead to more personalized and effective bone implants, ultimately improving patient outcomes and transforming the field of biomedical engineering. The integration of 3D printing with advanced imaging techniques will further enhance the design and fabrication of custom implants.