Fused Filament Fabrication of PEEK: A Review of Process-Structure-Property Relationships

Abstract

Poly (ether ether ketone) (PEEK) is a high-performance engineering thermoplastic polymer with potential for use in a variety of metal replacement applications due to its high strength to weight ratio. This combination of properties makes it an ideal material for use in the production of bespoke replacement parts for out-of-earth manufacturing purposes, in particular on the International Space Station (ISS). Additive manufacturing (AM) may be employed for the production of these parts, as it has enabled new fabrication pathways for articles with complex design considerations. However, AM of PEEK via fused filament fabrication (FFF) encounters significant challenges, mostly stemming from the semi crystalline nature of PEEK and its associated high melting temperature. This makes PEEK highly susceptible to changes in processing conditions which leads to a large reported variation in the literature on the final performance of PEEK. This has limited the adaption of FFF printing of PEEK in space applications where quality assurance and reproducibility are paramount. In recent years, several research studies have examined the effect of printing parameters on the performance of the 3D-printed PEEK parts. The aim of the current review is to provide comprehensive information in relation to the process-structure-property relationships in FFF 3D-printing of PEEK to provide a clear baseline to the research community and assesses its potential for space applications, including out-of-earth manufacturing.

Manufacturing and Characterization of 3D Miniature Polymer Lattice Structures Using Fused Filament Fabrication

“…The validity of the results could be expanded to other feedstock materials, such as polycarbonate and possibly polyetheretherketone (PEEK). PEEK, a semi-crystalline thermoplastic with excellent biocompatibility and mechanical properties that could be printed using FFF processes [ 52 , 53 , 54 ], could be of special interest, as it would enable its use in applications such as orthopedic implants.…”

The Direct 3D Printing of Functional PEEK/Hydroxyapatite Composites via a Fused Filament Fabrication Approach

“…As such, the properties and subsequent performance of semi-crystalline PEEK materials produced through FFF 3D printing will strongly depend upon providing the correct processing parameters during printing. It is hypothesized that these could be carefully modified and controlled to minimise the normal inconsistency observed in their mechanical properties by allowing fine-tuning of the crystalline microstructure and would ultimately provide a direct and cost-effective route for 3D printing of PEEK/HA composites [ 25 ].…”

Additive Manufacturing of Wood Flour/PHA Composites Using Micro-Screw Extrusion: Effect of Device and Process Parameters on Performance

“…Figure 11 c shows the surface quality of samples printed at various nozzle temperature. The layers are even separated due to the poor interlayer bonding [ 33 ] when the nozzle temperature is 170 °C.…”