Polyetherimide in 3D printing: Pioneering non-metallic solutions for personalized orthopedic and traumatology hip prosthetics

Currently, Total Hip Replacement (THR) hip prosthetics are typically made from metallic materials using subtractive manufacturing, and they are not personalized. These materials, with higher densities than trabecular bone, can cause microfractures due to fatigue cycles. This study aims to demonstrate the feasibility of using Polyetherimide (PEI) as a rigid thermoplastic in additive manufacturing, offering a viable alternative for patient-specific prostheses in humans or pets. The starting point was a commercial prosthesis, a similar replica was 3D modelled, and test specimens were printed using ULTEM 1010 material. The PEI prosthesis meets outlined standards and offers an alternative for young, lightweight patients, and various pets. It does so by adapting to specific the patient's anatomical needs. Fatigue life was found to be the limiting factor, as the 392 N applied prosthesis, exceeded the million cycles limitation set for this study, prompting us to focus on the prosthesis' use on children, or small pets. •Commercial polyetherimide is effective as a biocompatible alternative in non-metallic implants via additive manufacturing.•The S–N curve has been extracted and used in FEM simulation to validate dynamic behavior.•The original geometry of the commercial hip prosthesis has been adapted to reduce stresses•The new polyetherimide printed prosthesis is applicable to young patients and pets, expanding its potential utility.