A method for manufacturing a mechanically strong and durable hybrid structure of polyethylene–hydroxyapatite composite and titanium alloy

Abstract The integration of polymer, metal, and ceramic materials in hybrid structures represents a potential but underexplored alternative for biomedical applications. Here, we present a methodology for manufacturing a mechanically strong and durable hybrid overlap structure from a composite of green high‐density polyethylene (HDPE) and hydroxyapatite (HA) compatibilized with HDPE‐ g ‐MAH joined to a substrate of Ti6Al4V alloy. This process involves laser structuring of micro‐scale grooves on the metal surface, followed by injection overmolding of the polymer composite. A hybrid overlap joint with strong interfacial anchoring was achieved, resulting in outstanding joining strength and fatigue life. This achievement holds significant promise for future biomedical applications. Highlights Joining of composite of HDPE–HA with Ti6Al4V alloy via injection overmolding Laser texturing was effective in improving mechanical interlocking A hybrid joint with high shear strength and fatigue life was developed The hybrid joint is promising for biomedical applications