Sand casting-inspired surface modification of 3D-printed porous polyetheretherketone scaffolds for enhancing osteogenesis

3D-printed polyetheretherketone (PEEK) scaffolds are developed as novel bone substitutes, however, their bioinert surface hinders osteogenesis and modifying PEEK scaffolds without blocking their inter-connected porous structure is challenged. In this study, 45S5 bioactive glasses (BG) were homogeneously coated on PEEK scaffolds inspired by traditional sand-casting. The structure of PEEK scaffolds was preserved under shaping effect of BG fillers. Modulus, coating yield and hydrophilicity of scaffolds after different thermal treatment time were comparatively investigated. Excellent hydroxyapatite-forming ability of BG-coated scaffolds was confirmed by mineralization study. In-vitro assessments, BG-coated scaffolds cultured with MC3T3-E1 cells presented potential as bone implants with excellent cytocompatibility and osteogenic properties. Following similar coating strategy, conductive particles, multi-component particles and template particles were also coated on PEEK surface. The proposed methodology highlights a useful approach towards producing tunable biomedical coatings and microstructure on porous PEEK scaffolds for bone tissue engineering.