Effects of material morphology and processing conditions on the characteristics of hydroxyapatite and high-density polyethylene biocomposites by selective laser sintering

Hydroxyapatite (HA), a ceramic to which bone inherently bonds, incorporated into a polymer matrix enhances the bioactivity of implants. In order to rapid-manufacture bioactive implants, selective laser sintering (SLS) has been used to fabricate HA and high-density polyethylene (HDPE) composite (HA-HDPE). The properties of SLS-fabricated specimens have been investigated. The main aspects to be considered in the SLS technology are the properties of the materials used in the process and processing parameters (PPs). HA-HDPE composite specimens have been fabricated using five different powders with variations in particle size (PS), PS distribution, and five different laser PPs. The sintering height, the width, and the shrinkage of the specimens were determined and the effects of the particles and PPs on the physical properties were investigated. The HA-HDPE specimens were found to be highly porous and the sintered density and porosity of the specimens were influenced by the PS and PPs. The interparticle connectivity and the pore size range of the specimens were found to be predominantly determined by the PS and to a lesser extent also influenced by the PPs. The strength of these specimens and the relationship with porosity are discussed.