Hydroxyapatite/polymer composite coatings of different volume ratios were produced using a Plastic Flame Spray (PFS) system. The intent of this processing is to obtain a coating with an optimal combination of biological and mechanical properties of these two materials for skeletal implants. The composite coatings were produced with a mechanical blend of EMMA and hydroxyapatite powder from a fluidized bed powder feeder. Characterization was conducted by scanning electron microscopy on the surface morphology, polished cross-sections and fracture surface morphology of the coatings. The bioactivity of the coatings was evaluated with a calcium ion meter, and the stress-strain behavior was investigated by tensile testing. The biological and mechanical properties were found to be related to the volume and the distribution of the hydroxyapatite in the polymer matrix.

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