Osteosynthesis implants

The number of bone fractures in Germany is steadily rising, posing economic challenges for healthcare systems. Osteosynthesis is often necessary to stabilize complex fractures. To date, metal implants (steel, titanium) have been the primary choice. However, these have significant drawbacks: they cause artifacts in imaging (CT/MRI) and usually require a risky second surgery to remove the material.

A current research project, funded by the Industrial Joint Research (IGF), addresses this issue and is developing novel, resorbable fiber-reinforced implants at the DITF’s Biomedical Engineering Technology Center (BMT). Unlike previous biodegradable polymers, which lacked the strength required for load-bearing bones, these systems utilize highly stretched fibers. Through additive manufacturing (3D printing), the implants can be designed to withstand specific loads and tailored to individual patients. This reduces the amount of material required and prevents growth disturbances in children. The goal is stable, temporary fixation that completely dissolves in the body after healing.

For the first time, the project combines resorbable polymers with resorbable highly stretched yarns that are incorporated into implants via additive manufacturing. Initial investigations have shown that even with a low yarn content, an increase in tensile strength and a significantly increased stiffness - which is also desired - can be achieved.

As the project progresses, the yarn content in the implant will be maximized and optimized for specific loads to ensure suitability for load-bearing applications. By the end of the project, prototype components - defined in collaboration with an expert committee - will be designed and manufactured into demonstrators using the newly developed production process.