Osteoconductive hydroxyapatite coated PEEK for spinal fusion surgery

•Highly dense and well-adhered hydroxyapatite (HA) is deposited on PEEK using aerosol deposition.•After hydrothermal annealing, the crystallinity of the HA coating is remarkably enhanced without thermal degradation of the PEEK substrate.•Adhesion strength of HA coating to PEEK substrate remained relatively unchanged after hydrothermal annealing. Polyetheretherketone (PEEK) has attracted much interest as biomaterial for interbody fusion cages due to its similar stiffness to bone and good radio-transparency for post-op visualization. Hydroxyapatite (HA) coating stimulates bone growth to the medical implant. The objective of this work is to make an implant consisting of biocompatible PEEK with an osteoconductive HA surface for spinal or orthopedic applications. Highly dense and well-adhered HA coating was developed on medical-grade PEEK using aerosol deposition (AD) without thermal degradation of the PEEK. The HA coating had a dense microstructure with no cracks or pores, and showed good adhesion to PEEK at adhesion strengths above 14.3MPa. The crystallinity of the HA coating was remarkably enhanced by hydrothermal annealing as post-deposition heat-treatment. In addition, in vitro and in vivo biocompatibility of PEEK, in terms of cell adhesion morphology, cell proliferation, differentiation, and bone-to-implant contact ratio, were remarkably enhanced by the HA coating through AD.