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Material Extrusion 3D Printing of PEEK-Based Composites

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 mol...

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Autores principales: Hanemann, Thomas, Klein, Alexander, Baumgärtner, Siegfried, Jung, Judith, Wilhelm, David, Antusch, Steffen
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10458592/
https://www.ncbi.nlm.nih.gov/pubmed/37631469
http://dx.doi.org/10.3390/polym15163412
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author Hanemann, Thomas
Klein, Alexander
Baumgärtner, Siegfried
Jung, Judith
Wilhelm, David
Antusch, Steffen
author_facet Hanemann, Thomas
Klein, Alexander
Baumgärtner, Siegfried
Jung, Judith
Wilhelm, David
Antusch, Steffen
author_sort Hanemann, Thomas
collection PubMed
description 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.
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spelling pubmed-104585922023-08-27 Material Extrusion 3D Printing of PEEK-Based Composites Hanemann, Thomas Klein, Alexander Baumgärtner, Siegfried Jung, Judith Wilhelm, David Antusch, Steffen Polymers (Basel) Article 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. MDPI 2023-08-15 /pmc/articles/PMC10458592/ /pubmed/37631469 http://dx.doi.org/10.3390/polym15163412 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Hanemann, Thomas
Klein, Alexander
Baumgärtner, Siegfried
Jung, Judith
Wilhelm, David
Antusch, Steffen
Material Extrusion 3D Printing of PEEK-Based Composites
title Material Extrusion 3D Printing of PEEK-Based Composites
title_full Material Extrusion 3D Printing of PEEK-Based Composites
title_fullStr Material Extrusion 3D Printing of PEEK-Based Composites
title_full_unstemmed Material Extrusion 3D Printing of PEEK-Based Composites
title_short Material Extrusion 3D Printing of PEEK-Based Composites
title_sort material extrusion 3d printing of peek-based composites
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10458592/
https://www.ncbi.nlm.nih.gov/pubmed/37631469
http://dx.doi.org/10.3390/polym15163412
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