Highly efficient preparation of multi-angle continuous carbon fibre reinforced hydroxyapatite composites by electrostatic splitting method

An electrostatic splitting device was self-designed and manufactured for highly efficient preparation of multi-angle continuous carbon fibre (CF)-reinforced ceramic-based composites and was used to prepare multi-angle continuous CF and nano-hydroxyapatite (nHA)-coated CF reinforced HA composites with improved CF dispersion and content. The compressive strength of sintered [0°/90°] CF reinforced hydroxyapatite (CF/HA) composites is more than two and a half times that of hydroxyapatite and is superior to that of cortical bone (26.42–110.7%). Compared with hydroxyapatite, fracture toughness of [0°/0°], [0°/90°] and [− 45°/+ 45°] CF/HA composites increase by 28.83%, 66.32% and 115.95%, respectively. The strength and fracture toughness (30.2 MPa·m1/2) of [− 45°/+ 45°] CF/HA bioceramics display synchronously improving. Micromechanical property and crack propagation process of the composites were simulated in depth. Based on optimised dispersion and arrangement of CF, the introduction of nHA coating enhances the mechanical properties of nHA-coated CF reinforced HA composites because nHA coating can block the generation and propagation of cracks.