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Material innovation continues to enhance what orthopedic implants, instruments and devices can do. Specialty metals, bioresorbable polymers, advanced plastics and bioceramics are evolving to meet increasing performance demands.
Recent developments from six orthopedic contract suppliers highlight the ways that material science continues to evolve and expand what’s possible in the development of difference-making new products.
EU MDR-compliant Stainless Steel
Industry trends suggest that medical device manufacturers are shifting their focus away from European markets and concentrating R&D efforts in other regions. Future innovations could therefore progress through other regulatory frameworks, such as FDA.
In that context, it wouldn’t be surprising to see contract manufacturers and OEMs experiment with alternative materials in non-European markets, effectively using those regions as proving grounds for innovation. This dynamic creates an opportunity to advance new material solutions in the U.S. and other markets that operate under different regulatory systems.
To that end, Carpenter Technology is advancing alternatives to traditional cobalt chrome with BioDur 108, a nitrogen-strengthened, nickel- and cobalt-free austenitic stainless steel.
BioDur 108 achieves wear resistance comparable to cobalt chrome molybdenum, and pin-on-disc testing over one million cycles showed similar mass loss and surface roughness, making the material a scalable and practical option for articulating components.
The material is designed to address tightening global regulations, particularly under EU MDR, as orthopedic OEMs look to innovate device designs.
Cobalt is now classified as a carcinogen, mutagen and reproductive toxin. From a chemical compliance standpoint, any device containing 0.1% cobalt or more must carry a warning label, which directly affects many alloys traditionally used in orthopedic implants, including stainless steels and cobalt chrome.
By eliminating nickel and cobalt from the material composition equation, BioDur complies with EU MDR regulations and is optimized for mechanical performance, allowing OEMs to move forward with new product development projects without sacrificing design freedom or clinical performance.
High-performance Plastics
Ensinger recently received a Gold-level Environmental Excellence Award from the International Association of Plastics Distribution because of its commitment to responsible manufacturing. In addition to being recognized for its sustainability leadership, the company is expanding the role of advanced polymers.
Ensinger offers TECAPEEK MT XRO Blue, an X-ray opaque, biocompatible PEEK tailored for complex orthopedic applications. Beyond solid polymers, Ensinger is also engineering particle foams made from high-performance thermoplastics such as PEEK, PESU and polycarbonate.
The foams combine lightweight design and energy absorption with the mechanical and thermal performance of engineering plastics for structural components that combine weight reduction and durability.
Expanding Biomaterials Portfolio
Evonik recently signed a supply agreement with SINTX Technologies enabling Evonik to manufacture SINTX’s proprietary silicon nitride–PEEK (SiN/PEEK) compound that’s designed for the AI-assisted additive manufacturing of patient-specific implants. The agreement enables immediate production using SINTX’s existing U.S. infrastructure and supports both humanitarian-use spine implants and future regulatory clearances.
Evonik’s RESOMER bioresorbable polymers include polycaprolactone (PCL), polylactic acid (PLA) and polylactic-co-glycolic acid (PLGA) offer biodegradable options for numerous applications, including screws, suture anchors and fracture plates. The company’s VESTAKEEP PEEK is a solid option for producing spinal implants due to its bone-like properties and radiolucency, which allows surgeons to place implants accurately during surgery and monitor the patient healing process.
Looking ahead to 2026, Evonik is focused on developing VECOLLAN, a recombinant, non-animal-derived collagen-like biomaterial that the company introduced in September. VECOLLAN features tunable properties, high purity levels and sustainable production with a fermentation-based process that can be used to produce hydrogels that capitalize on collagen’s role in tissue regeneration.
Validation of VECOLLAN and its material availability is expected this year.
Expanding Cannulated Bar Capabilities
Forécreu strengthened its global footprint with last year’s acquisition of Grover Precision, a move that expanded its manufacturing presence in the U.S. The combined companies boast expertise in cannulated bar production.
By adding Grover’s cannulated bar technology, gun drilling services and U.S.-based manufacturing facility, Forécreu has added the capacity to supply OEMs with cannulated bars, tubes and solid bars in stainless steels and titanium alloys.
Boosting Bioceramic Production
Himed’s development of hydroxyapatite (HA) began in the early 1990s, when plasma spray coatings were still an emerging technology. Rather than outsourcing inorganic materials and controlling the plasma spray process, the company invested in vertically integrated manufacturing initially supported by a collaboration with NYU’s calcium phosphate research lab.
Today, Himed develops HA for coatings and tricalcium phosphate (TCP) for resorbable bone grafts and fillers. The company focuses on material optimization by adjusting chemistry, morphology and performance based on the specific application needs of OEM customers.
Himed has invested in large-scale furnace capacity, which will be online this year, enabling production volumes of up to four tons per week for select material processes. The company’s R&D team supports custom material development in close collaboration with OEMs and its Bioceramics Center of Excellence, which was launched in 2024, is beginning to turn development projects into commercialization successes.
Advancing Metal-Free Joint Replacement
Last June, the first U.S. cases were performed using Maxx Orthopedics’ Freedom Total Knee System, which contains Invibio’s advanced PEEK-OPTIMA femoral component, as part of a staged IDE clinical study.
PEEK-OPTIMA is a high-performance biomaterial polymer that Invibio engineers to closely match the modulus and flexural strength of cortical bone, helping support bone density over time. Its radiolucent properties allow for artifact-free imaging during surgery and post-implantation device monitoring.
The material offers a modulus and flexural strength closer to cortical bone than traditional metals, supporting bone density preservation.
Maxx Orthopedics’ successful early cases represent growing interest in polymer-based, load-bearing components and signal a potential shift in knee replacement material strategies.
Companies like these will be part of the more than 200 orthopedic suppliers exhibiting at OMTEC 2026. Register now to reserve your spot at the conference and connect with their reps to learn more about their offerings.
Also check out BONEZONE’s exclusive Supplier Directory to explore comprehensive listings of companies with materials capabilities.
