PEEK based cranial reconstruction using thermal assisted incremental sheet forming

Compared to conventional sheet forming operations, incremental sheet forming (ISF) is a flexible forming technique that can achieve higher formability in terms of localized deformation. Due to excellent mechanical properties and X-ray penetration, polyether-ether-ketone (PEEK) is an ideal alternative to titanium alloy and stainless steel in orthopedic applications. In this study, a 3-axis desktop manufacturing system has been fabricated to investigate the temperature-dependent formability of PEEK in terms of manufacturing the cranial plate by using the ISF technique. Meanwhile, the forming force, temperature distribution, geometrical accuracy, and thermal properties were obtained and analyzed. The findings indicate that the ISF technique provides technological and economic advantages in cranial reconstruction by using PEEK.