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Fabricated using fused filament fabrication (FFF), these implants were evaluated against conventional Ti\u20106AL\u20104V titanium alloy counterparts through a combination of experimental analysis and finite element method (FEM) simulations. The novel designs of discontinuous carbon fiber\u2010PEEK and continuous carbon fiber\u2010Nylon composites exhibited enhanced performance, reducing screw pull\u2010out force by nearly 50% relative to Ti\u20106AL\u20104V. Furthermore, the thermoplastic composites demonstrated significantly higher bio\u2010elastic coupling strain energy density (SED), indicating superior capacity to promote bone healing and callus formation. A comprehensive multi\u2010criteria evaluation\u2014including metrics on screw loosening, bone remodeling, and resorption\u2014revealed that the 3D\u2010printed composites outperformed titanium by 33%\u201365%. These results provide design guidelines for FFF 3D\u2010printed composite implants, offering considerable promise as customizable and effective alternatives to conventional metal implants.<\/jats:p>","DOI":"10.1002\/jbm.b.35682","type":"journal-article","created":{"date-parts":[[2025,11,4]],"date-time":"2025-11-04T06:30:25Z","timestamp":1762237825000},"update-policy":"https:\/\/doi.org\/10.1002\/crossmark_policy","source":"Crossref","is-referenced-by-count":1,"title":["Innovative Biomechanical Design and Performance of Carbon Fiber\u2010Thermoplastic Implants via Additive Manufacturing"],"prefix":"10.1002","volume":"113","author":[{"given":"Vacharat","family":"Thongsumrit","sequence":"first","affiliation":[{"name":"Advanced Materials and Structures Laboratory (AMASS) and Center for Lightweight Materials Design and Manufacturing, Department of Mechanical Engineering, Faculty of Engineering King Mongkut's University of Technology Thonburi  Thung Khru Bangkok Thailand"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Phorntep","family":"Chaitaweepakorn","sequence":"additional","affiliation":[{"name":"Advanced Materials and Structures Laboratory (AMASS) and Center for Lightweight Materials Design and Manufacturing, Department of Mechanical Engineering, Faculty of Engineering King Mongkut's University of Technology Thonburi  Thung Khru Bangkok Thailand"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Pajjittar","family":"Kolimart","sequence":"additional","affiliation":[{"name":"Advanced Materials and Structures Laboratory (AMASS) and Center for Lightweight Materials Design and Manufacturing, Department of Mechanical Engineering, Faculty of Engineering King Mongkut's University of Technology Thonburi  Thung Khru Bangkok Thailand"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Khomkrit","family":"Pingkarawat","sequence":"additional","affiliation":[{"name":"PTT Global Chemical Public Company Limited  Bangkok Thailand"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-5223-4867","authenticated-orcid":false,"given":"Wares","family":"Chancharoen","sequence":"additional","affiliation":[{"name":"Laboratory of Artificial Intelligence and Innovation in Medicine (AIIM) Princess Srisavangavadhana Faculty of Medicine, Chulabhorn Royal Academy  Bangkok Thailand"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Sontipee","family":"Aimmanee","sequence":"additional","affiliation":[{"name":"Advanced Materials and Structures Laboratory (AMASS) and Center for Lightweight Materials Design and Manufacturing, Department of Mechanical Engineering, Faculty of Engineering King Mongkut's University of Technology Thonburi  Thung Khru Bangkok Thailand"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"311","published-online":{"date-parts":[[2025,11,3]]},"reference":[{"key":"e_1_2_8_2_1","doi-asserted-by":"publisher","DOI":"10.1016\/j.injury.2006.04.130"},{"issue":"1","key":"e_1_2_8_3_1","first-page":"20","article-title":"Changes in Bone Mineral Density in the Proximal Femur After Cementless Total Hip Arthroplasty","volume":"86","author":"Brodner W.","year":"2004","journal-title":"Journal of Bone & Joint Surgery British Volume"},{"key":"e_1_2_8_4_1","doi-asserted-by":"publisher","DOI":"10.1016\/j.bone.2013.09.004"},{"issue":"3","key":"e_1_2_8_5_1","first-page":"175","article-title":"Wolff's Law and Bone's Structural Adaptations to Mechanical Usage: An Overview for Clinicians","volume":"64","author":"Frost H. 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