A method for manufacturing a mechanically strong and durable hybrid structure of polyethylene–hydroxyapatite composite and titanium alloy

The integration of polymer, metal, and ceramic materials in hybrid structures represents a potential but underexplored alternative for biomedical applications. Here, we present a methodology for manufacturing a mechanically strong and durable hybrid overlap structure from a composite of green high-density polyethylene (HDPE) and hydroxyapatite (HA) compatibilized with HDPE-g-MAH joined to a substrate of Ti6Al4V alloy. This process involves laser structuring of micro-scale grooves on the metal surface, followed by injection overmolding of the polymer composite. A hybrid overlap joint with strong interfacial anchoring was achieved, resulting in outstanding joining strength and fatigue life. This achievement holds significant promise for future biomedical applications. Highlights: Joining of composite of HDPE–HA with Ti6Al4V alloy via injection overmolding Laser texturing was effective in improving mechanical interlocking A hybrid joint with high shear strength and fatigue life was developed The hybrid joint is promising for biomedical applications.