Surface Finishing of FDM-Fabricated Amorphous Polyetheretherketone and Its Carbon-Fiber-Reinforced Composite by Dry Milling

Abstract

In recent years, many investigations have been devoted to fused deposition modeling (FDM) of high-performance polymer-polyetheretherketone (PEEK) and carbon-fiber-reinforced PEEK (CF/PEEK) for biomedical and aerospace applications. However, the staircase effect naturally brought about by FDM restricts further applications of 3D-printed PEEK and its composites in high-temperature molds, medical implants, and precision components, which require better or customized surface qualities. Hence, this work aimed to reduce the staircase effect and improve the surface quality of 3D-printed PEEK and CF/PEEK parts by dry milling of the fluctuant exterior surface. The co-dependency between 3D printing parameters (raster angle and layer thickness) and milling parameters (depth of cut, spindle speed, and feed rate per tooth) were investigated through experiments. The difference in removal mechanisms for PEEK and CF/PEEK was revealed. It was confirmed that the smearing effect enhanced the surface quality based on the morphology analysis and the simulation model. Both the raster angle of +45°/−45° and the small layer thickness could improve the surface quality of these 3D-printed polymers after dry milling. A large depth of cut and a large feed rate per tooth were likely to deteriorate the finished polymer surface. The spindle speed could influence the morphologies without significant changes in roughness values. Finally, a demonstration was performed to verify that dry milling of 3D-printed amorphous PEEK and CF/PEEK parts could lead to a high surface quality for critical requirements.

An Investigation on the Hardness of Polylactic Acid Parts Fabricated via Fused Deposition Modeling

“…The FDM method is popular due to its highly flexibility and process speed, but the durability of the printed material is the major concern, especially for products applicated in an outdoor environment [ 5 ]. The popular materials used in the FDM method include polylactic acid (PLA) [ 6 ], acrylonitrile butadiene styrene (ABS) [ 7 , 8 ], polyethylene terephthalate (PET) [ 9 ], polyethylene terephthalate glycol (PETG) [ 10 , 11 ], and others composite fibers [ 12 , 13 , 14 ]. The digital prototype of the part is usually created by CAD software and exported as an STL file.…”

Mechanical Properties of Fused Deposition Modeling of Polyetheretherketone (PEEK) and Interest for Dental Restorations: A Systematic Review

“…Several parameters influence the printing of PEEK via FDM technology and, thus, its mechanical properties: the layer thickness [ 21 , 22 , 23 , 24 , 25 , 26 ], the nozzle diameter [ 27 ], the printing speed [ 23 , 27 ], the printing temperature [ 22 , 23 , 24 , 27 , 28 , 29 ], the chamber temperature [ 28 , 30 , 31 ], the raster angle [ 21 , 24 , 25 , 26 , 32 , 33 ], the build plate orientation [ 16 , 24 , 34 , 35 ], the infill rate [ 35 ], the PEEK modifications [ 34 , 36 , 37 ] and the possible post-treatment [ 25 , 31 , 36 , 38 ].…”

PEEK Biomaterial in Long-Term Provisional Implant Restorations: A Review

“…In screw-retained implant prostheses, a PEEK abutment screw has an advantage over a metal screw due to similar elastic properties [ 47 ]. In addition, the stress distribution in implant and abutment can be improved by composing the PEEK and its fiber-reinforced composites [ 47 , 48 , 49 , 50 , 51 ]. Figure 8 shows the surfaces of a 3D-printed PEEK and PEEK matrix composite [ 52 ].…”

“…In addition, it is necessary to improve the fracture properties of PEEK implants. Considering this, the development of a PEEK composite by adding continuous multidirectional carbon fibers may help to improve the properties, but more studies are needed [ 51 ].…”

“… Surfaces 3D morphology and scanning electron microscopy of printed PEEK and Carbon fiber/PEEK composite: ( a ) PEEK with 0.1 layer thickness; ( b ) carbon fiber/PEEK with 0.1 mm layer thickness; ( c ) PEEK part with 0.2 mm layer thickness; ( d ) carbon fiber/PEEK part with LT 0.2 mm layer thickness; ( e ) scanning electron microscopy image of the PEEK part with 0.1 mm layer thickness; ( f ) scanning electron microscopy image of the carbon fiber/PEEK part with 0.1 mm layer thickness [ 51 ]. …”