Effect of 3D Printing Process Parameters and Heat Treatment Conditions on the Mechanical Properties and Microstructure of PEEK Parts

Zhen, Honglei; Zhao, Bin; Quan, Long; Fu, Junyu

doi:10.3390/polym15092209

Cited by 15 publications

(10 citation statements)

References 38 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In a similar work, Zhen at al. investigated the impact of different printing parameters, like filling angle, extrusion rate and printing orientation (horizontal or vertical on the built platform), by applying a 0.4 mm nozzle and a constant printing temperature of 430 °C on the resulting mechanical properties [ 31 ]. Interestingly, they found for all investigated different extrusion rates, filling angles, and printing orientation smaller values for the tensile strength (max.…”

Section: Resultsmentioning

confidence: 99%

See 1 more Smart Citation

Material Extrusion 3D Printing of PEEK-Based Composites

et al. 2023

View full text Add to dashboard Cite

High-performance thermoplastics like polyetheretherketone (PEEK), with their outstanding thermal stability, mechanical properties and chemical stability, have great potential for various structural applications. Combining with additive manufacturing methods extends further PEEK usage, e.g., as a mold insert material in polymer melt processing like injection molding. Mold inserts must possess a certain mechanical stability, a low surface roughness as well as a good thermal conductivity for the temperature control during the molding process. With this in mind, the commercially available high-performance thermoplastic PEEK was doped with small amounts of carbon nanotubes (CNT, 6 wt%) and copper particles (10 wt%) targeting enhanced thermomechanical properties and a higher thermal conductivity. The composites were realized by a commercial combined compounder and filament maker for the usage in a material extrusion (MEX)-based 3D-printer following the fused filament fabrication (FFF) principle. Commercial filaments made from PEEK and carbon fiber reinforced PEEK were used as reference systems. The impact of the filler and the MEX printing conditions like printing temperature, printing speed and infill orientation on the PEEK properties were characterized comprehensively by tensile testing, fracture imaging and surface roughness measurements. In addition, the thermal conductivity was determined by the laser-flash method in combination with differential scanning calorimetry and Archimedes density measurement. The addition of fillers did not alter the measured tensile strength in comparison to pure PEEK significantly. The fracture images showed a good printing quality without the MEX-typical voids between and within the deposited layers. Higher printing temperatures caused a reduction of the surface roughness and, in some cases, an enhanced ductile behavior. The thermal conductivity could be increased by the addition of the CNTs. Following the given results, the most critical process step is the compounding procedure, because for a reliable process–parameter–property relationship, a homogeneous particle distribution in the polymer matrix yielding a reliable filament quality is essential.

show abstract

Section: Resultsmentioning

confidence: 99%

“…70 MPa). Unfortunately, the authors do not include neither the PEEKs vendor or data for tensile strength, taken from a data sheet [ 31 ]. Rahmatabadi and coworkers investigated the dependence of the mechanical properties with printing parameters like printing speed, printing orientation, and layer thickness a.o.…”

Section: Resultsmentioning

confidence: 99%

Material Extrusion 3D Printing of PEEK-Based Composites

et al. 2023

View full text Add to dashboard Cite

show abstract

“…Various factors within the FDM process can impact the mechanical properties of 3D-printed parts. For instance, parameters such as layer thickness [4][5][6], infill density, printing temperature, and filament type [7][8][9][10][11][12][13] all play a significant role in determining the mechanical characteristics of the produced object. Also, the post-processing treatments can considerably influence the mechanical behavior of 3D-printed parts [14][15][16][17].…”

Section: Introductionmentioning

confidence: 99%

Analyzing Sustainable 3D Printing Processes: Mechanical, Thermal, and Crystallographic Insights

Portoacă,

Diniță,

Tănase

et al. 2024

Polymers

View full text Add to dashboard Cite

In this study, the objective was to optimize energy consumption in the fused deposition modeling (FDM) 3D printing process via a detailed analysis of printing parameters. By utilizing thermal analysis techniques, this research aimed to identify lower printing temperatures that could lead to reduced energy usage. Experimental analysis was conducted using a three-level L9 Taguchi orthogonal array, which involved a systematic combination of different extruder temperatures and cooling fan capacities. Furthermore, the research incorporated differential scanning calorimetry (DSC) and X-ray diffraction (XRD) methods to analyze the thermal properties and crystallinity of the 3D-printed specimens. The results indicated that temperature was a key factor affecting crystallinity, with samples printed at 190 °C and 60% fan capacity showing the highest mean values. By conducting a multi-objective desirability analysis, the optimal conditions for maximizing ultimate tensile strength (UTS), tensile modulus, and elongation at break while minimizing energy consumption for PLA 3D-printed samples were determined to be a temperature of 180 °C and a fan speed of 80%.

show abstract

“…Feedstock from pressurised syringes is deposited fluidly, often at room temperature, eliminating the need for melting [ 13 , 14 , 15 ]. Honglei et al [ 16 ] examined 3D-printed PEEK parts in their research, studying the effects of the extrusion rate, filling angle, and orientation on mechanical properties. Optimal results were achieved at 1.0× extrusion rate, variable ±10° angle fillings, and vertical printing, with heat treatment at 300 °C for 2 h significantly improving crystallinity and strength to nearly 80% of the injection-moulded parts’ strengths.…”

Section: Introductionmentioning

confidence: 99%

Design and Modification of a Material Extrusion 3D Printer to Manufacture Functional Gradient PEEK Components

Ritter,

McNiffe,

Higgins

et al. 2023

Polymers

View full text Add to dashboard Cite

In recent years, the creative use of polymers has been expanded as the range of achievable material properties and options for manufacturing and post-processing continually grows. The main goal of this research was to design and develop a fully-functioning material extrusion additive manufacturing device with the capability to produce functionally graded high-temperature thermoplastic PEEK (polyether ether ketone) materials through the manipulation of microstructure during manufacturing. Five different strategies to control the chamber temperature and crystallinity were investigated, and concepts of thermal control were introduced to govern the crystallisation and cooling mechanics during the extrusion process. The interaction of individually deposited beads of material during the printing process was investigated using scanning electron microscopy to observe and quantify the porosity levels and interlayer bonding strength, which affect the quality of the final part. Functional testing of the printed parts was carried out to identify crystallinity, boundary layer adhesion, and mechanical behaviour. Furnace cooling and annealing were found to be the most effective methods, resulting in the highest crystallinity of the part. Finally, a functionally graded material cylindrical part was printed successfully, incorporating both low and high crystalline regions.

show abstract

Effect of 3D Printing Process Parameters and Heat Treatment Conditions on the Mechanical Properties and Microstructure of PEEK Parts

Cited by 15 publications

References 38 publications

Material Extrusion 3D Printing of PEEK-Based Composites

Material Extrusion 3D Printing of PEEK-Based Composites

Analyzing Sustainable 3D Printing Processes: Mechanical, Thermal, and Crystallographic Insights

Design and Modification of a Material Extrusion 3D Printer to Manufacture Functional Gradient PEEK Components

Contact Info

Product

Resources

About