The aim of this study was to produce an individually shaped medical implant from a 3D database and to evaluate the biological behavior of a laser sintered poly(ether ether ketone) (PEEK) implant with incorporated osteoconductive bone materials in porcine bone defects. Laser sintered PEEK samples containing ß-tricalciumphosphate (ß-TCP) were implanted into critical size defects in the frontal skull of ten pigs. Compression moulded pure PEEK was used as a reference material. The bone-implant interface was histomorphometrically analysed after 6, 12, and 24 weeks. Histomorphometrical evaluations after 24 weeks revealed that the superficially located ß-TCP was in contact with the surrounding bone, whereas the other groups were fibrous encapsulated. Interfacial shear strength was significantly higher for the ß-TCP containing group in comparison to the compression moulded PEEK group (p = 0.004) and the laser sintered PEEK group. The laser sintered PEEK implants seem to be attractive as bone substitutes for reconstructive surgery due to their individually constructed 3D shape and biocompatibility.
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