Functionalized, biocompatible, and impermeable nanoscale coatings for PEEK

Biologically compatible coatings that provide hermetic seal could resolve a major technological hurdle in the attempt to replace metals with polymers for biochips and active medical implants. The use of amorphous carbon/diamond like carbon (a-C:H) coatings to hermetically seal and biologically enhance polyether-ether-ketone (PEEK) for biomedical device integration in the human body was investigated. The PEEK coating functionality (sp3/sp2 ratio), hardness and thickness (70–200 nm) were controlled, by varying H₂ and N₂ concentration during the plasma operation with CH₄. a-C:H coatings having the highest indentation modulus of 13.5 GPa, originate out of a CH₄ (90%) rich composition. Even in a mixture of 70/30 H₂/CH₄ the hardness is 4.76 GPa, corresponding to hard and dense coatings. In all tested conditions of deposition coatings hardens was sufficient for the purpose of PEEK implants modification. The synthesized (a-C:H) nanoscale coatings were not water permeable as measured by the hydrolysis test, resolving the traditional challenge of swelling in wet environment. The hardness of the coatings showed strong correlations with the thickness, surprisingly however, with no correlations with the sp3/sp2 ratio. Selected non water permeable nanoscale coating on PEEK showed strong bioactivity by being viable for human osteoblast (hFOB) and human fibroblast (hGF) cells without toxicity issues. No correlation was observed between the coatings sp3/sp2 ratio and biological performance.