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These partially porous devices have a high surface area and aim to integrate with cancellous bone of the distal femur and proximal tibia to increase the stability of the implant. Incidences of metal-hypersensitivity and macrophage-stimulated osteolysis have motivated the development of a non-metal alternative in the form of \u00a0 polyaryletherketone (PAEK) implants. We hypothesized that highly complex porous PAEK components could be additively manufactured to withstand the mechanical forces of the knee, while still allowing for bone ingrowth. Taguchi optimization was used to investigate parameters and porous geometries that achieved the highest ultimate load in 45\u00b0 shear-compression. Micro-CT was used to evaluate the quality of the print porosity for each experimental group. Low-melt (LM) PAEK sample means exceeded all polyetheretherketone (PEEK) means, and geometry and percent porosity were found to be the most significant parameters for LM PAEK, while nozzle temperature, chamber temperature and layer height were the most significant for PEEK (\n                    <jats:italic>p<\/jats:italic>\n                    \u2009&lt;\u20090.05). All samples passed the theoretical worst-case scenario of\u2009~\u20095.5\u00a0kN ultimate load in 45\u00b0 shear. The mean errors for percent porosity were not significantly different (\n                    <jats:italic>p<\/jats:italic>\n                    \u2009&gt;\u20090.05) and measured to be \u2212\u20098.46% and \u2212\u200912.25% for PEEK and LM PAEK groups, respectively. This work serves as a proof-of-concept for 3D printing highly porous non-metal metaphyseal sleeves\/cones without compromising on strength.\n                  <\/jats:p>","DOI":"10.1007\/s10439-026-04042-8","type":"journal-article","created":{"date-parts":[[2026,2,19]],"date-time":"2026-02-19T18:14:53Z","timestamp":1771524893000},"page":"2337-2345","update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Additively Manufactured Partially Porous PAEK Topologies for Proximal Tibia Revision Cones and Sleeves"],"prefix":"10.1007","volume":"54","author":[{"ORCID":"https:\/\/orcid.org\/0000-0003-1535-6125","authenticated-orcid":false,"given":"Paul M.","family":"DeSantis","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Emma","family":"Barnes","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Abigail","family":"Tetteh","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"James A.","family":"Smith","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Drew","family":"Mike","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Corey","family":"Perine","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Steven M.","family":"Kurtz","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"297","published-online":{"date-parts":[[2026,2,19]]},"reference":[{"issue":"9","key":"4042_CR1","doi-asserted-by":"publisher","first-page":"2663","DOI":"10.1016\/j.arth.2017.03.066","volume":"32","author":"RE Delanois","year":"2017","unstructured":"Delanois, R. 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Paul M. DeSantis, Emma Barnes, and Abigail Tetteh declare no conflicts of interest. James Smith and Steven M. Kurtz are members of Gyroid LLC, a scientific and technical consulting firm. Gyroid provides consulting services to medical device companies and receive fees for those services. Steven M. Kurtz also receives research support from the following companies or suppliers as a Principal Investigator: Celanese, Ceramtec, Invibio, Mitsubishi Chemical Advanced Materials, Orthofix, 3Spine, Seqens, Enovis, Orthoplastics, SINTX Technologies, and Stryker. Drew Mike and Corey Perine are paid employees of Maxx Orthopedics, Inc., a medical device company, but results and findings presented in this study were obtained independently and without undue influence.","order":2,"name":"Ethics","group":{"name":"EthicsHeading","label":"Disclosures"}}]}}