Selective laser fiber welding on woven polymer fabrics for biomedical applications

Localized cartilage damage is a common problem for younger patients. This can heal, but often results in a painful condition that requires intervention. A welded-woven three-dimensional polymer fabric has been suggested as a suitable cartilage replacement because such materials closely match the mechanical properties of cartilage. However, such materials fare poorly when evaluated with respect to wear. A microscopic investigation of wear mechanisms showed that it is critical that the fibers not deflect laterally under a normal load. This observation led to the use of a new process for selective laser welding of the surface layers of three-dimensional fabrics in order to improve their wear resistance. Experimental evaluations were made in a pin-on-disc arrangement with a biomimetic loading. All materials used in the studies have previously been used in orthopedic devices or meet the requirements for United States Pharmacopeial Convention (USP) Class VI biocompatibility approval. The wear rates were significantly reduced and the lifespan of the fabrics was markedly improved due to surface welding, making this a viable option for cartilage replacement in vivo. [Display omitted] •A new welded-woven orthogonal fabric has been developed for biomedical applications.•A laser welding technique has been developed for improving the strength and properties of three-dimensional fabrics.•The welded-woven orthogonal fabrics outperformed the non-welded versions of the orthogonal fabrics•There is potential for this material to be used in other tribological applications in industries beyond healthcare.