Comparison of 3D-printed poly-ether-ether-ketone and traditional implant materials in cranioplasty

The advancement in material science and processing methods has led to the continuous development of novel biomaterial implants and bone flap manufacturing methods in cranioplasty. This retrospective study aimed to investigate the outcomes and clinical prognosis of patients undergoing skull repair using fused filament fabrication (FFF)-printed poly-ether-ether-ketone (PEEK) implants versus traditional implants (i.e., autologous bone and titanium mesh). We recruited patients who underwent cranioplasty (performed by senior surgeons) between January 2021 and March 2023. A total of 66 patients who underwent cranioplasty were included in this study and divided into three groups according to the material used for their respective implants: (i) three-dimensional (3D)-printed PEEK, (ii) autologous bone, and (iii) titanium mesh. Infection, epilepsy, and transplant failure did not occur in any of the three groups. Additionally, there were no statistically significant differences in terms of implant-related complications and patient neurological function among the three groups 6 months after discharge (P > 0.05). This study demonstrated the feasibility, safety, and aesthetics of 3D-printed PEEK implants for clinical application. Nonetheless, 3D printing may be a promising translational technology for the future of neurosurgery.