PEEK Pectus Bar: Evaluation of a New Material for Pectus Excavatum Repair in Children and Teenagers.

Abstract

The Nuss procedure for Pectus Excavatum repair has relied on metallic bars for the past 3 decades. The technical efforts have focused on the improvement of stability and the reduction of the associated risks. However, some challenges still remain, like metal ion release, thoracic wall mechanic behavior, and the need for implant remotion. In other areas of surgery, polyetheretherketone (PEEK), a polymer that allows 3D printing, has shown mechanical properties closer to human bone and excellent biocompatibility, becoming an alternative material for medical implants. Herein, we present the mechanic evaluation of a novel PEEK Pectus Bar (PPB) that was manufactured via fused deposition modeling with 100% infill density. Mechanical validation included quasi-static bending tests, cyclic loading, and finite element analysis (FEA). Dynamic impact simulations replicated anterior-posterior thoracic loading to assess energy absorption capacity. The PPB demonstrated linear mechanical response with experimental-FEA correlation using an elastic modulus of 1500 MPa. Cyclic tests revealed characteristic viscoelastic behavior with energy dissipation stabilization and no progressive structural damage. Dynamic impact simulation yielded energy absorption of 14.55 J, comparable to human ribs under similar loading conditions. The 3D-printed PPB exhibits mechanical behavior aligned with human rib compliance while maintaining structural integrity under physiological and high-rate loading, supporting clinical investigation as an alternative to metallic implants.