Creating the Next Generation of Antimicrobial Hybrid Composites for Biomedical Applications: Manufacturing, Multiscale Modeling, and Mechanical Characterization

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The need for custom-fit, strong, and long-lasting implants for bone fracture fixation still poses major challenges to researchers and surgeons, as metallic implants fail to optimally transfer the load to the host bone. Despite modern advances in implants' designs and treatment options, complications associated with metal implants remain unresolved. The long term objective of my proposed research program is to develop an innovative manufacturing platform to fabricate the next generation of hybrid composite implants with antimicrobial capabilities and advanced performance. Specifically, my research program aims to achieve the following short term objectives: 1) Create a new, integrated platform that combines a 6DOF robotic arm, a 3D extruder, and a UVC-LED device to systematically 3D print fracture fixation implants with improved properties. 2) Develop an antimicrobial coating technology to improve the natural fibres' wettability and also protect them from mold, bacteria, and other microbial contaminants. 3) Fabricate the hybrid composite implants using the new platform and perform multiscale experimental characterization. 4) Develop a new multiscale, physics-based model to predict the mechanical behaviour and the long term durability of these antimicrobial, 3D-printed composite implants. To achieve these goals, we will design and integrate an innovative UVC-LED device into a 3D printing platform so that the hybrid fibres can be sterilized while they are being fabricated. We will transform a multipurpose robot platform to incorporate a 3D extruder in order to 3D print both natural and synthetic fibres. We will improve the properties of the fibres by using a low cost, non-leaching, and environmentally friendly preservative. We will perform multiscale testing of the 3D-printed hybrid composites to investigate their mechanical behaviour using advanced destructive and non-destructive testing techniques. We will also develop, and validate a new multiscale model to predict their damage and fatigue behaviour.  From an economic and environmental perspective, the proposed research program is vital for Canada's manufacturing industry. It will advance the state-of-the-art manufacturing of fibre-reinforced composites by improving our understanding of the effects of UV-LED sterilization and hybridization on their technical properties, processing, and performance. It will also guide the development of new, high performance, lightweight, and cost effective biocomposite structures. Custom-fit healthcare implants, reduced environmental impact, and cost savings are among the immediate benefits of the proposed technology. Canada will also benefit from the highly skilled HQP who will be trained and supported by this research program. A total of 12 HQPs, including 50% women and 50% men, will be trained in a highly collaborative, equitable, diverse, and inclusive environment in various areas relevant to the natural sciences and engineering (NSE) field.