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1
Comelli, Cleiton André, Richard Davies, HenkJan van der Pol, and Oana Ghita. "PEEK filament characteristics before and after extrusion within fused filament fabrication process." Journal of Materials Science 57, no. 1 (2022): 766–88. http://dx.doi.org/10.1007/s10853-021-06652-0.
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AbstractThe heating and extrusion process in fused filament fabrication (FFF) is significantly shorter than the conventional extrusion process where longer heating times and significant pressure are applied. For this reason, it is important to understand whether the crystal history of the feedstock is fully erased through the FFF process and whether the FFF process can be tailored further by engineering the crystallization of the feedstock filaments. In this context, a methodology for evaluating the influence of morphology and mechanical properties on different feedstock and extruded filaments is proposed. Filaments with three different PEEK 450G crystalline structures (standard crystallinity, drawn filament and amorphous filament) were selected and evaluated, before and after free extrusion. The resulting morphology, crystallinity and mechanical properties of the extruded filaments were compared against the feedstock properties. X-ray diffraction (XRD), transmission electron microscopy (TEM), differential and fast scanning calorimetry (DSC/FDSC) and tensile test were the techniques used to evaluate the materials. The results showed clear differences in the properties of the feedstock materials, while the analysis of the extruded filaments points to a homogenization of the resulting material producing mostly similar mechanical properties. However, the use of the drawn filament highlighted a statistically significant improvement in crystallinity and mechanical performance, especially in strain values. This conclusion suggests the innovative possibility of improving the quality of manufactured parts by tailoring the microstructure of the feedstock material used in the FFF process. Graphical abstract
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Hanemann, Thomas, Alexander Klein, Siegfried Baumgärtner, Judith Jung, David Wilhelm, and Steffen Antusch. "Material Extrusion 3D Printing of PEEK-Based Composites." Polymers 15, no. 16 (2023): 3412. http://dx.doi.org/10.3390/polym15163412.
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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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Ladipo, Taiwo, Leonard Masu, and Patrick Nziu. "Experimental Analysis of Crystallinity and Mechanical Properties for Fused Filament Printed Polyetherketone Composites." Journal of Engineering 2023 (October 11, 2023): 1–10. http://dx.doi.org/10.1155/2023/6687928.
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The objective of this article is to examine the impacts of molybdenum disulphide (MoS2) and graphite-filled (Gr) polyetheretherketone (PEEK) composites that have been fabricated through 3D printing on their mechanical properties and crystallinity. Seven samples and thirty-five dog bones were produced using different filament strands to conduct the analysis. Before extrusion into filaments, the solid lubricants, MoS2, and graphite were uniformly dispersed within the PEEK through mechanical blending. At a concentration of 10 wt.%, the PEEK/MoS2 composites exhibited the highest tensile strength, measuring approximately 104 MPa, while the PEEK/Gr composites displayed the lowest tensile strength at the same concentration, approximately 36 MPa. In addition, the PEEK/MoS2 composites demonstrated better elongation, approximately 4.7%, compared to the PEEK/Gr composites, which exhibited approximately 2.3% elongation. X-ray diffraction (XRD) data revealed that neither MoS2 nor graphite significantly interacted with the PEEK matrix. The degree of crystallinity, as determined by density matrices, indicated that the printed PEEK composites possessed a higher level of crystallinity, approximately 62% at a concentration of 5 wt.%, than the calculated values. This suggests that the filament-making and 3D printing processes had an annealing effect. The significance of solid lubricant content and dispersion in shaping the mechanical properties and crystal formation of 3D-printed PEEK composites is emphasized in this study. Furthermore, this research provides valuable insights for optimizing PEEK-based materials for various applications.
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LADIPO, TAIWO. "Experimental Analysis of Crystallinity and Mechanical Properties for Fused Filament Printed Polyetherketone Composites." Journal of Engineering 2023 (October 11, 2023): 10. https://doi.org/10.1155/2023/6687928.
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The objective of this article is to examine the impacts of Molybdenum disulphide (MoS2) and graphite-filled (Gr) Polyetheretherketone (PEEK) composites that have been fabricated through 3D printing on their mechanical properties and crystallinity. To conduct the analysis, seven samples and thirty-five dog bones were produced using different filament strands. Before extrusion into filaments, the solid lubricants, MoS2 and graphite, were uniformly dispersed within the PEEK through mechanical blending. At a concentration of 10 wt.%, the PEEK/MoS2 composites exhibited the highest tensile strength, measuring approximately 104 MPa, while the PEEK/Gr composites displayed the lowest tensile strength at the same concentration, approximately 36 MPa. Additionally, the PEEK/MoS2 composites demonstrated better elongation, approximately 4.7%, in comparison to the PEEK/Gr composites, which exhibited approximately 2.3% elongation. X-ray diffraction (XRD) data revealed that neither MoS2 nor graphite significantly interacted with the PEEK matrix. The degree of crystallinity, as determined by density matrices, indicated that the printed PEEK composites possessed a higher level of crystallinity, approximately 62% at a concentration of 5 wt.%, than the calculated values. This suggests that the filament-making and 3D printing processes had an annealing effect. The significance of solid lubricant content and dispersion in shaping the mechanical properties and crystal formation of 3D-printed PEEK composites is emphasized in this study. Furthermore, this research provides valuable insights for optimizing PEEK-based materials for various applications.
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Paleari, Lorenzo, Mario Bragaglia, Francesco Fabbrocino, Raimondo Luciano, and Francesca Nanni. "Self-Monitoring Performance of 3D-Printed Poly-Ether-Ether-Ketone Carbon Nanotube Composites." Polymers 15, no. 1 (2022): 8. http://dx.doi.org/10.3390/polym15010008.
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In this paper, poly-ether-ether-ketone (PEEK) carbon-nanotube (CNT) self-monitoring composites at different levels of filler loading (i.e., 3, 5 and 10% by weight) have been extruded as 3D-printable filaments, showing gauge factor values of 14.5, 3.36 and 1.99, respectively. CNT composite filaments of 3 and 5 wt% were 3D-printed into tensile samples, while the PEEK 10CNT filament was found to be barely printable. The 3D-printed PEEK 3CNT and PEEK 5CNT composites presented piezo-resistive behavior, with an increase in electrical resistance under mechanical stress, and showed an average gauge factor of 4.46 and 2.03, respectively. Mechanical tests highlighted that 3D-printed samples have a laminate-like behavior, presenting ultimate tensile strength that is always higher than 60 MPa, hence they offer the possibility to detect damages in an orthogonal direction to the applied load wit high sensitivity.
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Doyle, Lucía, Xabier Pérez-Ferrero, Javier García-Molleja, Ricardo Losada, Pablo Romero-Rodríguez, and Juan P. Fernández-Blázquez. "Fused Filament Fabrication of Slow-Crystallizing Polyaryletherketones: Crystallinity and Mechanical Properties Linked to Processing and Post-Treatment Parameters." Polymers 16, no. 23 (2024): 3354. http://dx.doi.org/10.3390/polym16233354.
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Recent advancements in thermoplastics within the polyaryletherketone (PAEK) family have enhanced additive manufacturing (AM) potential in fields like aerospace and defense. Polyetheretherketone (PEEK), the best-studied PAEK, faces limitations in AM due to its fast crystallization, which causes poor inter-filament bonding and warping. This study investigated alternative, slow-crystallizing PAEK polymers: polyetherketoneketone (PEKK-A) and AM-200, a PEEK-based copolymer. Both can be printed in an amorphous state and then annealed to improve crystallinity and mechanical properties. Despite their potential, these materials have been minimally explored for AM. Our analysis compared the mechanical performance of as-printed and annealed samples and showed that slow-crystallizing PAEKs outperform fast-crystallizing PEEK. As-printed PEKK-A and AM-200 parts reached tensile strengths of 69 MPa and 47 MPa, respectively, which are about 80% of the values for injection-molded parts. In contrast, PEEK achieves only 25% due to poor inter-layer bonding. Annealing increased crystallinity (15.7% for PEKK-A, 19% for AM-200), simultaneously leading to a coalescence of smaller pores into larger ones, which affected mechanical integrity. Annealing strengthened the printed filament direction, while Z-direction strength remained limited by interlayer adhesion. Our work provides new insights into optimizing these relationships to expand the applicability of PAEK in additive manufacturing.
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Baek, Inwoo, Oeun Kwon, Chul-Min Lim, Kyoung Youl Park, and Chang-Jun Bae. "3D PEEK Objects Fabricated by Fused Filament Fabrication (FFF)." Materials 15, no. 3 (2022): 898. http://dx.doi.org/10.3390/ma15030898.
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PEEK (poly ether ether ketone) materials printed using FFF 3D printing have been actively studied on applying electronic devices in satellites owing to their excellent light weight and thermal resistance. However, the PEEK FFF process generated cavities inside due to large shrinkage has degraded both mechanical integrity and printing reliability. Here, we have investigated the correlations between nozzle temperatures and PEEK printing behaviors such as the reliability of printed line width and surface roughness. As the temperature increased from 360 to 380 °C, the width of the printed line showed a tendency to decrease. However, the width of PEEK printed lines re-increased from 350 to 426 μm at the nozzle temperatures between 380 and 400 °C, associated with solid to liquid-like phase transition and printed out distorted and disconnected lines. The surface roughness of PEEK objects increased from 49 to 55 μm as the nozzle temperature increased from 380 to 400 °C, where PEEK is melted down and quickly solidified based on more energy and additional heating time at higher printing temperatures at 400 °C. Based on these printing trends, a reliability analysis of the printed line was performed. The printed line formed the most uniform width at 380 °C and had a highest Weibull coefficient of 28.6 using the reliability analysis technique called Weibull modulus.
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Cicala, Gianluca, Alberta Latteri, Barbara Del Curto, Alessio Lo Russo, Giuseppe Recca, and Silvia Farè. "Engineering Thermoplastics for Additive Manufacturing: A Critical Perspective with Experimental Evidence to Support Functional Applications." Journal of Applied Biomaterials & Functional Materials 15, no. 1 (2017): 10–18. http://dx.doi.org/10.5301/jabfm.5000343.
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Background Among additive manufacturing techniques, the filament-based technique involves what is referred to as fused deposition modeling (FDM). FDM materials are currently limited to a selected number of polymers. The present study focused on investigating the potential of using high-end engineering polymers in FDM. In addition, a critical review of the materials available on the market compared with those studied here was completed. Methods Different engineering thermoplastics, ranging from industrial grade polycarbonates to novel polyetheretherketones (PEEKs), were processed by FDM. Prior to this, for innovative filaments based on PEEK, extrusion processing was carried out. Mechanical properties (i.e., tensile and flexural) were investigated for each extruded material. An industrial-type FDM machine (Stratasys Fortus® 400 mc) was used to fully characterize the effect of printing parameters on the mechanical properties of polycarbonate. The obtained properties were compared with samples obtained by injection molding. Finally, FDM samples made of PEEK were also characterized and compared with those obtained by injection molding. Results The effect of raster to raster air gap and raster angle on tensile and flexural properties of printed PC was evidenced; the potential of PEEK filaments, as novel FDM material, was highlighted in comparison to state of the art materials. Conclusions Comparison with injection molded parts allowed to better understand FDM potential for functional applications. The study discussed pros and cons of the different materials. Finally, the development of novel PEEK filaments achieved important results offering a novel solution to the market when high mechanical and thermal properties are required.
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Dua, Rupak, Zuri Rashad, Joy Spears, Grace Dunn, and Micaela Maxwell. "Applications of 3D-Printed PEEK via Fused Filament Fabrication: A Systematic Review." Polymers 13, no. 22 (2021): 4046. http://dx.doi.org/10.3390/polym13224046.
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Polyether ether ketone (PEEK) is an organic polymer that has excellent mechanical, chemical properties and can be additively manufactured (3D-printed) with ease. The use of 3D-printed PEEK has been growing in many fields. This article systematically reviews the current status of 3D-printed PEEK that has been used in various areas, including medical, chemical, aerospace, and electronics. A search of the use of 3D-printed PEEK articles published until September 2021 in various fields was performed using various databases. After reviewing the articles, and those which matched the inclusion criteria set for this systematic review, we found that the printing of PEEK is mainly performed by fused filament fabrication (FFF) or fused deposition modeling (FDM) printers. Based on the results of this systematic review, it was concluded that PEEK is a versatile material, and 3D-printed PEEK is finding applications in numerous industries. However, most of the applications are still in the research phase. Still, given how the research on PEEK is progressing and its additive manufacturing, it will soon be commercialized for many applications in numerous industries.
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Harding, Matthew J., Sarah Brady, Heather O'Connor, et al. "3D printing of PEEK reactors for flow chemistry and continuous chemical processing." Reaction Chemistry & Engineering 5, no. 4 (2020): 728–35. http://dx.doi.org/10.1039/c9re00408d.
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Carpenter, Chris. "Composite 3D Printing Allows for Optimization of Backup Rings for HP/HT Applications." Journal of Petroleum Technology 77, no. 03 (2025): 63–66. https://doi.org/10.2118/0325-0063-jpt.
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_ This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper IPTC 23353, “Backup-Ring Optimization for High-Temperature and High-Pressure Applications Through Dynamic Composition Modification in Composite 3D Printing,” by Joshua T. Green, SPE, and Ian A. Rybak, SPE, The University of Texas at El Paso, and Chad Glaesman, SPE, Halliburton. The paper has not been peer reviewed. Copyright 2024 International Petroleum Technology Conference. _ Performance optimization was demonstrated in thermoplastic sealing systems for oil and gas equipment using emerging technologies in 3D printing to manufacture multicomponent composite structures. A custom 3D printer was equipped with a patented print head designed for dynamic mixing of individual feed materials and paired with advanced print-planning procedures to enable fabrication of novel thermoplastic structures. In addition to supporting fabrication of sealing components for rapid response in oil and gas equipment, this technique provides a means of improving the overall performance of sealing systems without an increase in the size or complexity of the sealing assembly. Introduction The purpose of this study is to demonstrate the potential for performance improvements in sealing connections through innovation in flat-backup-ring (FBUR) architectures. A component-level approach to functional testing was taken with supplementation from more-traditional materials analysis. The focus of investigation for this study is sealing connections with static O-rings supported by a single FBUR. Filaments composed of base resin alone were paired with filaments reinforced with carbon fiber (CF) to enable control over fiber volume fraction. Pressure-vessel testing was used to measure peak extrusion pressure and deformation after long periods of steady-state loading using hydraulic differential pressure. This study explores the potential for gains with the goal of optimizing multiple performance metrics when constrained by other design inputs such as material selection and geometry. In effect, the authors investigate composite architectures that can improve performance without altering resin or reinforcement material and without changing the size or shape of the FBUR. Methods Materials Selection. Polyether ether ketone (PEEK) is a popular base resin for FBURs in completion tool applications, and chopped CF is a common reinforcement used to increase the modulus of PEEK. PEEK is a favored resin for applications in oil and gas because of its broad fluid compatibility and mechanical characteristics at high temperatures. PEEK components typically are machined from injection- or compression-molded stock; however, at the time of this study, no known commercial fused-filament-fabrication (FFF) filaments are solely composed of comparable grades of PEEK resin because most filaments include additives to assist with printability. PEEK and PEEK+CF filaments were selected for high-temperature printing with a conventional all-metal hot end. 4043D-grade polylactic acid (PLA) and PLA+CF were selected for printing at lower temperatures suitable for the active-mixing hot end. Each pair of filaments included an unfilled grade to serve as a base resin and a corresponding fiber-loaded grade. All filaments used in this study featured a nominal diameter of 1.75 mm.
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LADIPO, TAIWO. "Mechanical and Tribological Performance of Polyetheretherketone Composites using Tabletop 3D Printer." International Journal of Engineering Trends and Technology 71, no. 11 (2023): 136–47. https://doi.org/10.14445/22315381/IJETT-V71I11P215.
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This article investigates the mechanical and tribological properties of 3D-printed Polyetheretherketone (PEEK)composites containing Molybdenum disulphide MoS2 and graphite fillers. 7 filament strands were created with varying weightpercentages to print 35 dog bones and 7-disc samples for further analysis. The results showed a 61% increase in tensile strengthof MoS2-filled PEEK (MoS2/PEEK) composite compared to plain PEEK. The filled PEEK had a reduced frictional responsetime and an average coefficient of friction of about 36% and 69 %, respectively. MoS2/PEEK showed superior wear resistanceof about 50% compared to graphite-impregnated PEEK (Gr./PEEK).
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Zanjanijam, Ali Reza, Ian Major, John G. Lyons, Ugo Lafont, and Declan M. Devine. "Fused Filament Fabrication of PEEK: A Review of Process-Structure-Property Relationships." Polymers 12, no. 8 (2020): 1665. http://dx.doi.org/10.3390/polym12081665.
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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.
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Palacios-Ibáñez, Belén, José J. Relinque, Daniel Moreno-Sánchez, et al. "Synthesis and Characterisation of ASA-PEEK Composites for Fused Filament Fabrication." Polymers 14, no. 3 (2022): 496. http://dx.doi.org/10.3390/polym14030496.
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In this paper, a series of polymer composites made from acrylonitrile-styrene-acrylate (ASA) and poly (ether ether ketone) (PEEK) were manufactured. ASA acts as a polymer matrix while PEEK is loaded in the form of micro-particles that act as a reinforcing filler. The composites were compounded by single screw extrusion and then, different specimens were manufactured either via injection moulding (IM) or fused filament fabrication (FFF). Two different types of PEEK (commercial and reused) in different concentrations (3 and 6 wt.%) were tested and their influence in the mechanical, structural, and thermal properties were studied. It was observed that reused PEEK enhanced the stiffness and tensile strength and thermal stability of the composites both, for injected and printed specimens. This evidences the suitability of these composites as potential candidates as novel materials with enhanced properties following an approach of circular economy.
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Gonçalves, Jordana, Patrícia Lima, Beate Krause, et al. "Electrically Conductive Polyetheretherketone Nanocomposite Filaments: From Production to Fused Deposition Modeling." Polymers 10, no. 8 (2018): 925. http://dx.doi.org/10.3390/polym10080925.
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The present work reports the production and characterization of polyetheretherketone (PEEK) nanocomposite filaments incorporating carbon nanotubes (CNT) and graphite nanoplates (GnP), electrically conductive and suitable for fused deposition modeling (FDM) processing. The nanocomposites were manufactured by melt mixing and those presenting electrical conductivity near 10 S/m were selected for the production of filaments for FDM. The extruded filaments were characterized for mechanical and thermal conductivity, polymer crystallinity, thermal relaxation, nanoparticle dispersion, thermoelectric effect, and coefficient of friction. They presented electrical conductivity in the range of 1.5 to 13.1 S/m, as well as good mechanical performance and higher thermal conductivity compared to PEEK. The addition of GnP improved the composites’ melt processability, maintained the electrical conductivity at target level, and reduced the coefficient of friction by up to 60%. Finally, three-dimensional (3D) printed test specimens were produced, showing a Young’s modulus and ultimate tensile strength comparable to those of the filaments, but a lower strain at break and electrical conductivity. This was attributed to the presence of large voids in the part, revealing the need for 3D printing parameter optimization. Finally, filament production was up-scaled to kilogram scale maintaining the properties of the research-scale filaments.
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Singh, Abhishek, and Sarah Hitchcock-DeGregori. "A Peek into Tropomyosin Unfolding on the Actin Filament." Biophysical Journal 96, no. 3 (2009): 332a. http://dx.doi.org/10.1016/j.bpj.2008.12.1671.
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Onggar, Toty, Leopold Alexander Frankenbach, and Chokri Cherif. "Investigations of the Interface Design of Polyetheretherketone Filament Yarn Considering Plasma Torch Treatment." Coatings 14, no. 11 (2024): 1424. http://dx.doi.org/10.3390/coatings14111424.
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Taking advantage of its high-temperature resistance and elongation properties, conductive-coated polyetheretherketone (PEEK) filament yarn can be used as a textile-based electroconductive functional element, in particular as a strain sensor. This study describes the development of electrical conductivity on an inert PEEK filament surface by the deposition of metallic nickel (Ni) layers via an electroless galvanic plating process. To enhance the adhesion properties of the nickel layer, both PEEK multifilament and monofilament yarn surfaces were metalized by plasma torch pretreatment, followed by nickel plating. Electrical characterizations indicate the potential of nickel-coated PEEK for structural monitoring in textile-reinforced composites. In addition, surface energy measurements before and after plasma torch pretreatment, surface morphology, nickel layer thickness, chemical structure changes, and mechanical properties were analyzed and compared with untreated PEEK. The thickness of the Ni layer was measured and showed an average thickness of 1.25 µm for the multifilament yarn and 3.36 µm for the monofilament yarn. FTIR analysis confirmed the presence of new functional groups on the PEEK surface after plasma torch pretreatment, indicating a successful modification of the surface chemistry. Mechanical testing showed an increase in tensile strength after plasma torch pretreatment but a decrease after nickel plating. In conclusion, this study successfully developed conductive PEEK yarns through plasma torch pretreatment and nickel plating.
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Rodzeń, Krzysztof, Mary Josephine McIvor, Preetam K. Sharma, et al. "The Surface Characterisation of Fused Filament Fabricated (FFF) 3D Printed PEEK/Hydroxyapatite Composites." Polymers 13, no. 18 (2021): 3117. http://dx.doi.org/10.3390/polym13183117.
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Polyetheretherketone (PEEK) is a high-performance thermoplastic polymer which has found increasing application in orthopaedics and has shown a lot of promise for ‘made-to-measure’ implants via additive manufacturing approaches. However, PEEK is bioinert and needs to undergo surface modification to make it at least osteoconductive to ensure a more rapid, improved, and stable fixation that will last longer in vivo. One approach to solving this issue is to modify PEEK with bioactive agents such as hydroxyapatite (HA). The work reported in this study demonstrates the direct 3D printing of PEEK/HA composites of up to 30 weight percent (wt%) HA using a Fused Filament Fabrication (FFF) approach. The surface characteristics and in vitro properties of the composite materials were investigated. X-ray diffraction revealed the samples to be semi-crystalline in nature, with X-ray Photoelectron Spectroscopy and Time-of-Flight Secondary Ion Mass Spectrometry revealing HA materials were available in the uppermost surface of all the 3D printed samples. In vitro testing of the samples at 7 days demonstrated that the PEEK/HA composite surfaces supported the adherence and growth of viable U-2 OS osteoblast like cells. These results demonstrate that FFF can deliver bioactive HA on the surface of PEEK bio-composites in a one-step 3D printing process.
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Hanemann, Thomas, Alexander Klein, Siegfried Baumgärtner, Judith Jung, David Wilhelm, and Steffen Antusch. "Characterization of Material Extrusion-Printed Amorphous Poly(Ether Ketone Ketone) (PEKK) Parts." Polymers 17, no. 8 (2025): 1069. https://doi.org/10.3390/polym17081069.
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Poly(ether ketone ketone) (PEKK), as a representative of high-performance poly(aryl ether ketones), shows outstanding thermomechanical properties, opening up a huge range of different applications in various technical fields. Its appearance as a quasi-amorphous polymer with a certain suppression of the crystallization process facilitates melt processing via additive manufacturing processes like material extrusion (MEX), especially in fused filament fabrication (FFF). The quality of the printing process is proven in this work by tensile testing and surface roughness measurements of suitable specimens. The MEX printing of semicrystalline PEKK faces two major challenges: on the one hand, the very high printing temperature is in contrast to established engineering plastics, and on the other hand, it is difficult to avoid crystallization after printing. The first issue can be addressed by using suitably enhanced MEX printers and the second one by selecting adapted printing parameters. The measured Young’s modulus (3.49 GPa) and tensile strength (104 MPa) values are higher than the related vendors’ data given for filaments (3.0 GPa and 92 MPa, respectively). In addition, the temperature-dependent thermal conductivity is determined, and the values of well-established PEEK (poly(ether ether ketone)) in the temperature range from 20 to 180 °C are mostly slightly higher in comparison to the related PEKK data. Based on the results, PEKK can be a useful substitute for well-established PEEK because of their comparable properties. However, PEKK has a pronouncedly lower FFF printing temperature, combined with a reduced tendency of the device to warp after printing. A larger printed test part with some surface structures shows the improved printability of PEKK in comparison to PEEK.
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Rodzeń, Krzysztof, Preetam K. Sharma, Alistair McIlhagger, et al. "The Direct 3D Printing of Functional PEEK/Hydroxyapatite Composites via a Fused Filament Fabrication Approach." Polymers 13, no. 4 (2021): 545. http://dx.doi.org/10.3390/polym13040545.
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The manufacture of polyetheretherketone/hydroxyapatite (PEEK/HA) composites is seen as a viable approach to help enhance direct bone apposition in orthopaedic implants. A range of methods have been used to produce composites, including Selective Laser Sintering and injection moulding. Such techniques have drawbacks and lack flexibility to manufacture complex, custom-designed implants. 3D printing gets around many of the restraints and provides new opportunities for innovative solutions that are structurally suited to meet the needs of the patient. This work reports the direct 3D printing of extruded PEEK/HA composite filaments via a Fused Filament Fabrication (FFF) approach. In this work samples are 3D printed by a custom modified commercial printer Ultimaker 2+ (UM2+). SEM-EDX and µCT analyses show that HA particles are evenly distributed throughout the bulk and across the surface of the native 3D printed samples, with XRD highlighting up to 50% crystallinity and crystalline domains clearly observed in SEM and HR-TEM analyses. This highlights the favourable temperature conditions during 3D printing. The yield stress and ultimate tensile strength obtained for all the samples are comparable to human femoral cortical bone. The results show how FFF 3D printing of PEEK/HA composites up to 30 wt% HA can be achieved.
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Vindokurov, Ilia, Yulia Pirogova, Mikhail Tashkinov, and Vadim V. Silberschmidt. "Effect of Heat Treatment on Elastic Properties and Fracture Toughness of Fused Filament Fabricated PEEK for Biomedical Applications." Polymers 14, no. 24 (2022): 5521. http://dx.doi.org/10.3390/polym14245521.
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This work presents the results of an experimental investigation of the mechanical properties of polyetheretherketone (PEEK) specimens additively manufactured (AM) by using fused filament fabrication with different printing parameters and subjected to postprocessing heat treatment. Standard and compact tension samples were manufactured with a different infill angle using 0.4 mm and 0.6 mm nozzle diameters. Some of the samples were subjected to heat treatment at 220 °C after manufacturing. Tensile tests were conducted to determine the values of elastic modulus, tensile strength, as well as mode-I fracture toughness and critical strain energy release rate. Tensile properties of single-thread and as-delivered filaments were also studied. It was concluded that heat treatment significantly improved the elastic properties, tensile strength and fracture toughness of the AM PEEK samples: the fracture resistance increased by 33 to 45% depending on the stacking order, while the tensile strength increased by some 45–65%, with the elasticity modulus grown by up to 20%. Strain fields induced in specimens by crack propagation were captured with a digital image correlation technique and compared with results of numerical simulations implemented with the extended finite-element method (XFEM). Conclusions on the optimal parameters of 3D printing of PEEK were made.
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Honigmann, Philipp, Neha Sharma, Brando Okolo, Uwe Popp, Bilal Msallem, and Florian M. Thieringer. "Patient-Specific Surgical Implants Made of 3D Printed PEEK: Material, Technology, and Scope of Surgical Application." BioMed Research International 2018 (2018): 1–8. http://dx.doi.org/10.1155/2018/4520636.
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Additive manufacturing (AM) is rapidly gaining acceptance in the healthcare sector. Three-dimensional (3D) virtual surgical planning, fabrication of anatomical models, and patient-specific implants (PSI) are well-established processes in the surgical fields. Polyetheretherketone (PEEK) has been used, mainly in the reconstructive surgeries as a reliable alternative to other alloplastic materials for the fabrication of PSI. Recently, it has become possible to fabricate PEEK PSI with Fused Filament Fabrication (FFF) technology. 3D printing of PEEK using FFF allows construction of almost any complex design geometry, which cannot be manufactured using other technologies. In this study, we fabricated various PEEK PSI by FFF 3D printer in an effort to check the feasibility of manufacturing PEEK with 3D printing. Based on these preliminary results, PEEK can be successfully used as an appropriate biomaterial to reconstruct the surgical defects in a “biomimetic” design.
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Doyle, Lucía, Javier García-Molleja, Juan Pedro Fernández-Blázquez, and Carlos González. "Unraveling the Print–Structure–Property Relationships in the FFF of PEEK: A Critical Assessment of Print Parameters." Polymers 17, no. 11 (2025): 1444. https://doi.org/10.3390/polym17111444.
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Poly-ether ether ketone (PEEK) is a high-performance thermoplastic known for its excellent mechanical properties, making it relevant for aerospace and medical applications. Additive manufacturing (AM) represents a critical step towards integrating PEEK into these sectors, particularly for complex geometries and custom parts. However, the mechanical properties achieved through AM have not yet reached those obtained via conventional techniques. Recent studies have sought to optimize the printing parameters to bridge this gap, but their findings remain inconsistent and difficult to generalize—suggesting a strong dependence on the experimental conditions. This is partly due to the Fused Filament Fabrication of PEEK being an emerging technology, with many studies relying on in-house built printers. Moreover, the underlying microstructural mechanisms governing its performance have rarely been explored in depth. In this work, we establish clear processing–structure–property relationships by integrating a rigorous DoE approach with comprehensive microstructural characterization. Our results highlight the dominant role of the processing environment near the glass transition temperature in promoting chain mobility, enhancing the amorphous phase ordering, and improving the mechanical performance: crystallinity alone does not fully explain the mechanical behavior of additively manufactured PEEK. Further, higher nozzle temperatures lower the porosity and increase the filament bonding, while faster printing speeds reduce the crystallinity and increase the porosity, negatively affecting the mechanical integrity. The results of this study are generalizable to any FFF printer of PEEK. Other materials or printing technologies are out of the scope of this work.
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Herath, Chathura Nalendra, Bok Choon Kang, Jong Kwang Park, Yong Hwang Roh, and Beong Bok Hwang. "Breaking Elongation Properties of Hybrid Yarns by Commingling Process." Materials Science Forum 532-533 (December 2006): 337–40. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.337.
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This paper is concerned the breaking elongation properties of Carbon/Aramid-, Carbon/Glass- and Aramid/Glass- matrix hybridized commingling yarns. The hybrid yarns produced by commingling process were investigated in terms of breaking elongation property. In experiments, carbon (CF), aramid (AF), and glass (GF) filament yarns were combined. In this study, selected matrix materials include Polyether-ether-Keeton (PEEK), and polyester (PES), or polypropylene (PP). The volume content of filament in hybrid yarn cross section was maintained at 50% for both reinforced and matrix, ant hybrid yarns count at 600 tex, respectively. The reinforcement to matrix filament combination was selected as 1:1 proportion. The effect of different air pressures and material combinations was investigated in terms of breaking elongation. In experiments, each type of hybrid yarn sample has been tested 20 times at the testing speed of 10mm/min. under 3 bar of yarn clamping pressure. Since breaking elongation is one of most important properties in textile fiber, it was examined closely with reference to the first breaking point of commingling-hybrid yarns. It was concluded from experiments that hybrid yarns with higher breaking elongation and higher tensile strength tend to show better force-elongation relationship. It was also known from experiments that the combination of two reinforcement filament yarns gives always much better results than a single reinforcement filament yarns in terms of elongation property. GF/AF/matrix is shown very much better elongation properties. PP and PES gives higher elongation than PEEK as a matrix material.
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Basgul, Cemile, Paul DeSantis, Tabitha Derr, Noreen J. Hickok, Ryan M. Bock, and Steven M. Kurtz. "Exploring the mechanical strength, antimicrobial performance, and bioactivity of 3D-printed silicon nitride-PEEK composites in cervical spinal cages." International Journal of Bioprinting 10, no. 2 (2024): 2124. http://dx.doi.org/10.36922/ijb.2124.
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 In this study, our goal was to assess the suitability of a polyether-ether-ketone (PEEK) and silicon nitride (Si3N4) polymer composite for antimicrobial three-dimensional (3D)-printed cervical cages. Generic cage designs (PEEK and 15 vol.% Si3N4-PEEK) were 3D-printed, including solid and porous cage designs. Cages were tested in static compression, compression shear, and torsion per ASTM F2077. For antibacterial testing, virgin and composite filament samples were inoculated with Staphylococcus epidermidis and Escherichia coli. In vitro cell testing was conducted using MC3T3-E1 mouse preosteoblasts, where cell proliferation, cumulative mineralization, and osteogenic activity were measured. The 3D-printed PEEK and Si3N4-PEEK cages exhibited adequate mechanical strength for all designs, exceeding 14.7 kN in compression and 6.9 kN in compression shear. Si3N4-PEEK exhibited significantly lower bacterial adhesion levels, with a 93.9% reduction (1.21 log), and enhanced cell proliferation when compared to PEEK. Si3N4-PEEK would allow for custom fabrication of 3D-printed spinal implants that reduce the risk of infection compared to unfilled PEEK or metallic alloys.  
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Singh, Abhishek, and Sarah E. Hitchcock-DeGregori. "A Peek into Tropomyosin Binding and Unfolding on the Actin Filament." PLoS ONE 4, no. 7 (2009): e6336. http://dx.doi.org/10.1371/journal.pone.0006336.
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Colton, J., and D. Leach. "Processing parameters for filament winding thick-section PEEK/carbon fiber composites." Polymer Composites 13, no. 6 (1992): 427–34. http://dx.doi.org/10.1002/pc.750130605.
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Friedrich, K., N. Glienke, J. Flöck, F. Haupert, and S. A. Paipetis. "Reinforcement of Damaged Concrete Columns by Filament Winding of Thermoplastic Composites." Polymers and Polymer Composites 10, no. 4 (2002): 273–80. http://dx.doi.org/10.1177/096739110201000402.
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An experimental study was conducted to compare various composite systems with different fibres (E-glass and carbon) in two different thermoplastic matrices (PPS, PEEK) for their strengthening efficiency for wrapped concrete columns. The results indicated that the use of E-glass fibres within a polyphenylenesulfide matrix to externally reinforce concrete columns is quite effective. The carbon fibre PEEK based system does not show much improvement in the load carrying capacity. The thickness of wrap/radius of concrete column-ratio also has an influence on the strengthening efficiency. For example ten layers of glass fibre/PPS-tapes resulted in a five fold improvement of the compressive strength of the non-reinforced concrete. Predamaged samples with the same amount of reinforcement were still 4.5 times stronger than the undamaged, non-reinforced concrete.
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Han, Xingting, Neha Sharma, Zeqian Xu, et al. "An In Vitro Study of Osteoblast Response on Fused-Filament Fabrication 3D Printed PEEK for Dental and Cranio-Maxillofacial Implants." Journal of Clinical Medicine 8, no. 6 (2019): 771. http://dx.doi.org/10.3390/jcm8060771.
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Polyetheretherketone (PEEK) is a prime candidate to replace metallic implants and prostheses in orthopedic, spine and cranio-maxillofacial surgeries. Fused-filament fabrication (FFF) is an economical and efficient three-dimensional (3D) printing method to fabricate PEEK implants. However, studies pertaining to the bioactivity of FFF 3D printed PEEK are still lacking. In this study, FFF 3D printed PEEK samples were fabricated and modified with polishing and grit-blasting (three alumina sizes: 50, 120, and 250 µm) to achieve varying levels of surface roughness. In vitro cellular response of a human osteosarcoma cell line (SAOS-2 osteoblasts, cell adhesion, metabolic activity, and proliferation) on different sample surfaces of untreated, polished, and grit-blasted PEEK were evaluated. The results revealed that the initial cell adhesion on different sample surfaces was similar. However, after 5 days the untreated FFF 3D printed PEEK surfaces exhibited a significant increase in cell metabolic activity and proliferation with a higher density of osteoblasts compared with the polished and grit-blasted groups (p < 0.05). Therefore, untreated FFF 3D printed PEEK with high surface roughness and optimal printing structures might have great potential as an appropriate alloplastic biomaterial for reconstructive cranio-maxillofacial surgeries.
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Wang, Zhicheng. "Progress in the Preparation Process and Application of Carbon Fiber Reinforced PEEK Composites." MATEC Web of Conferences 386 (2023): 01009. http://dx.doi.org/10.1051/matecconf/202338601009.
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Due to their outstanding overall performances, carbon fiber/poly(ether-ether-ketone) (CF/PEEK) composites have attracted a lot of interest recently. High-performance CF/PEEK composites have many advantages such as high strength, good toughness, and high service temperature, which have been widely used in various high-precision fields. This paper reviews the research progress of the CF/PEEK composite molding process and its applications in view of the research hotspots in recent years, laying the foundation for the research on the preparation technology and industrial application of the material. CF/PEEK molding process mainly includes injection molding, press molding, filament winding, 3D Printing, and automated fiber placement (AFP). Different processing methods and material ratios result in CF/PEEK materials with different mechanical properties. Since CF/PEEK has its own unique advantages over traditional metal materials in terms of mechanical properties, corrosion resistance, and density, CF/PEEK materials can be used to replace metal materials in many applications, such as aviation and aerospace, biomedical field and automotive part.
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Abbas, Karim, Lukas Hedwig, Nicolae Balc, and Sebastian Bremen. "Advanced FFF of PEEK: Infill Strategies and Material Characteristics for Rapid Tooling." Polymers 15, no. 21 (2023): 4293. http://dx.doi.org/10.3390/polym15214293.
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Traditional vulcanization mold manufacturing is complex, costly, and under pressure due to shorter product lifecycles and diverse variations. Additive manufacturing using Fused Filament Fabrication and high-performance polymers like PEEK offer a promising future in this industry. This study assesses the compressive strength of various infill structures (honeycomb, grid, triangle, cubic, and gyroid) when considering two distinct build directions (Z, XY) to enhance PEEK’s economic and resource efficiency in rapid tooling. A comparison with PETG samples shows the behavior of the infill strategies. Additionally, a proof of concept illustrates the application of a PEEK mold in vulcanization. A peak compressive strength of 135.6 MPa was attained in specimens that were 100% solid and subjected to thermal post-treatment. This corresponds to a 20% strength improvement in the Z direction. In terms of time and mechanical properties, the anisotropic grid and isotropic cubic infill have emerged for use in rapid tooling. Furthermore, the study highlights that reducing the layer thickness from 0.15 mm to 0.1 mm can result in a 15% strength increase. The study unveils the successful utilization of a room-temperature FFF-printed PEEK mold in vulcanization injection molding. The parameters and infill strategies identified in this research enable the resource-efficient FFF printing of PEEK without compromising its strength properties. Using PEEK in rapid tooling allows a cost reduction of up to 70% in tool production.
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Rezvani Ghomi, Erfan, Saeideh Kholghi Eshkalak, Sunpreet Singh, Amutha Chinnappan, Seeram Ramakrishna, and Roger Narayan. "Fused filament printing of specialized biomedical devices: a state-of-the art review of technological feasibilities with PEEK." Rapid Prototyping Journal 27, no. 3 (2021): 592–616. http://dx.doi.org/10.1108/rpj-06-2020-0139.
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Purpose The potential implications of the three-dimensional printing (3DP) technology are growing enormously in the various health-care sectors, including surgical planning, manufacturing of patient-specific implants and developing anatomical models. Although a wide range of thermoplastic polymers are available as 3DP feedstock, yet obtaining biocompatible and structurally integrated biomedical devices is still challenging owing to various technical issues. Design/methodology/approach Polyether ether ketone (PEEK) is an organic and biocompatible compound material that is recently being used to fabricate complex design geometries and patient-specific implants through 3DP. However, the thermal and rheological features of PEEK make it difficult to process through the 3DP technologies, for instance, fused filament fabrication. The present review paper presents a state-of-the-art literature review of the 3DP of PEEK for potential biomedical applications. In particular, a special emphasis has been given on the existing technical hurdles and possible technological and processing solutions for improving the printability of PEEK. Findings The reviewed literature highlighted that there exist numerous scientific and technical means which can be adopted for improving the quality features of the 3D-printed PEEK-based biomedical structures. The discussed technological innovations will help the 3DP system to enhance the layer adhesion strength, structural stability, as well as enable the printing of high-performance thermoplastics. Originality/value The content of the present manuscript will motivate young scholars and senior scientists to work in exploring high-performance thermoplastics for 3DP applications.
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Honigmann, Philipp, Neha Sharma, Ralf Schumacher, Jasmine Rueegg, Mathias Haefeli, and Florian Thieringer. "In-Hospital 3D Printed Scaphoid Prosthesis Using Medical-Grade Polyetheretherketone (PEEK) Biomaterial." BioMed Research International 2021 (January 11, 2021): 1–7. http://dx.doi.org/10.1155/2021/1301028.
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Recently, three-dimensional (3D) printing has become increasingly popular in the medical sector for the production of anatomical biomodels, surgical guides, and prosthetics. With the availability of low-cost desktop 3D printers and affordable materials, the in-house or point-of-care manufacturing of biomodels and Class II medical devices has gained considerable attention in personalized medicine. Another projected development in medical 3D printing for personalized treatment is the in-house production of patient-specific implants (PSIs) for partial and total bone replacements made of medical-grade material such as polyetheretherketone (PEEK). We present the first in-hospital 3D printed scaphoid prosthesis using medical-grade PEEK with fused filament fabrication (FFF) 3D printing technology.
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Park, Kijung, Gayeon Kim, Heena No, Hyun Woo Jeon, and Gül E. Okudan Kremer. "Identification of Optimal Process Parameter Settings Based on Manufacturing Performance for Fused Filament Fabrication of CFR-PEEK." Applied Sciences 10, no. 13 (2020): 4630. http://dx.doi.org/10.3390/app10134630.
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Fused filament fabrication (FFF) has been proven to be an effective additive manufacturing technique for carbon fiber reinforced polyether–ether–ketone (CFR-PEEK) due to its practicality in use. However, the relationships between the process parameters and their trade-offs in manufacturing performance have not been extensively studied for CFR-PEEK although they are essential to identify the optimal parameter settings. This study therefore investigates the impact of critical FFF parameters (i.e., layer thickness, build orientation, and printing speed) on the manufacturing performance (i.e., printing time, dimensional accuracy, and material cost) of CFR-PEEK outputs. A full factorial design of the experiments is performed for each of the three sample designs to identify the optimal parameter combinations for each performance measure. In addition, multiple response optimization was used to derive optimal parameter settings for the overall performance. The results show that the optimal parameter settings depend on the performance measures regardless of the designs, and that the layer thickness plays a critical role in the performance trade-offs. In addition, lower layer thickness, horizontal orientation, and higher speed form the optimal settings to maximize the overall performance. The findings from this study indicate that FFF parameter settings for CFR-PEEK should be identified through multi-objective decision making that involves conflicts between the operational objectives for the parameter settings.
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Wang, Dingjie, Xingting Han, Feng Luo, et al. "Adhesive Property of 3D-Printed PEEK Abutments: Effects of Surface Treatment and Temporary Crown Material on Shear Bond Strength." Journal of Functional Biomaterials 13, no. 4 (2022): 288. http://dx.doi.org/10.3390/jfb13040288.
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Three-dimensionally printed polyetheretherketone (PEEK) materials are promising for fabricating customized dental abutments. This study aimed to investigate the adhesive property of a 3D-printed PEEK material. The effects of surface treatment and temporary crown materials on shear bond strength were evaluated. A total of 108 PEEK discs were 3D printed by fused-filament fabrication. Surface treatments, including sandblasting, abrasive paper grinding, and CO2 laser ablation, were applied to the PEEK discs, with the untreated specimens set as the control. Afterward, the surface topographies of each group were investigated by scanning electron microscopy (SEM, n = 1) and roughness measurements (n = 7). After preparing the bonding specimens with three temporary crown materials (Artificial teeth resin (ATR), 3M™ Filtek™ Supreme Flowable Restorative (FR), and Cool Temp NATURAL (CTN)), the shear bond strength was measured (n = 6), and the failure modes were analyzed by microscopy and SEM. The results showed that ATR exhibited a significantly higher shear bond strength compared to FR and CTN (p < 0.01), and the PEEK surfaces treated by sandblasting and abrasive paper grinding showed a statistically higher shear bond strength compared to the control (p < 0.05). For clinical application, the ATR material and subtractive surface treatments are recommended for 3D-printed PEEK abutments.
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Zheng, Jibao, Enchun Dong, Jianfeng Kang, et al. "Effects of Raster Angle and Material Components on Mechanical Properties of Polyether-Ether-Ketone/Calcium Silicate Scaffolds." Polymers 13, no. 15 (2021): 2547. http://dx.doi.org/10.3390/polym13152547.
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Polyetheretherketone (PEEK) was widely used in the fabrication of bone substitutes for its excellent chemical resistance, thermal stability and mechanical properties that were similar to those of natural bone tissue. However, the biological inertness restricted the osseointegration with surrounding bone tissue. In this study, calcium silicate (CS) was introduced to improve the bioactivity of PEEK. The PEEK/CS composites scaffolds with CS contents in gradient were fabricated with different raster angles via fused filament fabrication (FFF). With the CS content ranging from 0 to 40% wt, the crystallinity degree (from 16% to 30%) and surface roughness (from 0.13 ± 0.04 to 0.48 ± 0.062 μm) of PEEK/CS scaffolds was enhanced. Mechanical testing showed that the compressive modulus of the PEEK/CS scaffolds could be tuned in the range of 23.3–541.5 MPa. Under the same printing raster angle, the compressive strength reached the maximum with CS content of 20% wt. The deformation process and failure modes could be adjusted by changing the raster angle. Furthermore, the mapping relationships among the modulus, strength, raster angle and CS content were derived, providing guidance for the selection of printing parameters and the control of mechanical properties.
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Spece, H., T. Yu, A. W. Law, M. Marcolongo, and S. M. Kurtz. "3D printed porous PEEK created via fused filament fabrication for osteoconductive orthopaedic surfaces." Journal of the Mechanical Behavior of Biomedical Materials 109 (September 2020): 103850. http://dx.doi.org/10.1016/j.jmbbm.2020.103850.
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Khatri, Bilal, Manuel Francis Roth, and Frank Balle. "Ultrasonic Welding of Additively Manufactured PEEK and Carbon-Fiber-Reinforced PEEK with Integrated Energy Directors." Journal of Manufacturing and Materials Processing 7, no. 1 (2022): 2. http://dx.doi.org/10.3390/jmmp7010002.
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The thermoplastic polymer polyether ether ketone (PEEK) offers thermal and mechanical properties comparable to thermosetting polymers, while also being thermally re-processable and recyclable as well as compatible with fused filament fabrication (FFF). In this study, the feasibility of joining additively manufactured PEEK in pure and short carbon-fiber-reinforced form (CF-PEEK) is investigated. Coupon-level samples for both materials were fabricated using FFF with tailored integrated welding surfaces in the form of two different energy director (ED) shapes and joined through ultrasonic polymer welding. Using an energy-driven joining process, the two materials were systematically investigated with different welding parameters, such as welding force, oscillation amplitude and welding power, against the resulting weld quality. The strengths of the welded bonds were characterized using lap-shear tests and benchmarked against the monotonic properties of single 3D-printed samples, yielding ultimate lap-shear forces of 2.17kN and 1.97kN and tensile strengths of 3.24MPa and 3.79MPa for PEEK and CF-PEEK, respectively. The weld surfaces were microscopically imaged to characterize the failure behaviors of joints welded using different welding parameters. Samples welded with optimized welding parameters exhibited failures outside the welded region, indicating a higher weld-strength compared to that of the bulk. This study lays the foundation for using ultrasonic welding as a glue-free method to join 3D-printed high-performance thermoplastics to manufacture large load-bearing, as well as non-load-bearing, structures, while minimizing the time and cost limitations of FFF as a fabrication process.
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Federl, Dominik Jonas, and Abbas Al-Rjoub. "Influence of 3D-Printed PEEK on the Tribo-Corrosion Performance of Ti6Al4V Biomedical Alloy." Lubricants 13, no. 7 (2025): 283. https://doi.org/10.3390/lubricants13070283.
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This study investigates the tribo-corrosion behavior of Ti6Al4V biomedical alloy, when sliding against fused filament fabrication (FFF) 3D-printed polyether ether ketone (PEEK) pins in a phosphate-buffered saline (PBS) solution. This research aims to evaluate wear mechanisms and electrochemical responses under simulated physiological conditions, providing critical insights for enhancing the durability and performance of biomedical implants. Potentiodynamic polarization tests demonstrate that the Ti6Al4V alloy possesses excellent corrosion resistance, which is further enhanced under sliding conditions compared to the test without sliding. When tested against 3D-printed PEEK, the alloy exhibits a mixed wear mechanism characterized by both abrasive and adhesive wear. Open-circuit potential (OCP) measurement of Ti6Al4V demonstrates the alloy’s superior electrochemical stability, indicating high corrosion resistance and a favorable coefficient of friction. These findings highlight the potential of 3D-printed PEEK as a viable alternative for biomedical applications, offering rapid patient-specific prototyping, tunable mechanical properties, and improved surface adaptability compared to conventional materials.
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Mustafa, Mohammed Ahmed, S. Raja, Layth Abdulrasool A. L. Asadi, Nashrah Hani Jamadon, N. Rajeswari, and Avvaru Praveen Kumar. "A Decision-Making Carbon Reinforced Material Selection Model for Composite Polymers in Pipeline Applications." Advances in Polymer Technology 2023 (April 11, 2023): 1–9. http://dx.doi.org/10.1155/2023/6344193.
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Pipes are manufactured primarily through the extrusion process. One of the material extrusion processes in recent digital manufacturing is additive manufacturing’s fusion deposition modeling. Pipes are made from various materials such as metal and plastic/polymers, and the main challenge has been in selecting the pipe material for the customized application. For the creation of water-passing tubes, this research has chosen appropriate carbon-reinforced polymers that can be used with filament made of polyether ether ketone (PEEK) and polyethylene terephthalate glycol (PETG). For this goal, the analytical hierarchy process, also known as the AHP, is used to choose the best material based on factors such as cost, temperature resistance, printing speed, and mechanical properties of the material. The results revealed that PEEK-CF is a better material for the customized impeller application than PETG-CF. The PEEK-CF obtains the higher priority value of 0.6363, and the PETG-CF obtains 0.2791. This decision-making technique can be used to select other comparable customized applications.
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Di Benedetto, Ricardo Mello, Anderson Janotti, Guilherme Ferreira Gomes, Antonio Carlos Ancelotti Junior, and Edson Cocchieri Botelho. "Development of hybrid steel-commingled composites CF/PEEK/BwM by filament winding and thermoforming." Composites Science and Technology 218 (February 2022): 109174. http://dx.doi.org/10.1016/j.compscitech.2021.109174.
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Khashirova, Svetlana Yu, Azamat L. Slonov, Azamat A. Zhansitov, et al. "The Rheology of Polyether Ether Ketone Concentrated Suspensions for Powder Molding and 3D Printing." Polymers 16, no. 14 (2024): 1973. http://dx.doi.org/10.3390/polym16141973.
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The main goal of the work was to use rheological methods for assessing the properties of a composition based on polyether ether ketone (PEEK) to determine the concentration limits of the polymer in the composition and select the optimal content of this composition for powder molding. The rheological properties of highly filled suspensions based on PEEK and paraffin, as well as in paraffin–polyethylene mixtures at various component ratios, were studied. These materials are designed for powder injection molding and 3D printing. Suspensions with a PEEK powder content above 50% are not capable of flow and, with increasing pressure, slide along the surface of the channel. For compositions with a higher content (60 and 70 vol.%) PEEK, independence of the storage modulus from frequency is observed, which is typical for solids and confirms the assignment of such suspensions to elastic–plastic media. The introduction of high-density polyethylene into the composition helps improve the technological properties of suspensions, expanding the range of fluidity, although it leads to an increase in viscosity. In suspensions with a mixed composition of the liquid phase, with increasing temperature, a decrease in the storage modulus is observed at 120 °C and, on the contrary, an increase at 180 °C. The latter may be a consequence of the evaporation of paraffin and the softening of PEEK due to the approach to the glass transition temperature of the polymer. Suspensions with 40% PEEK content have an optimal set of rheological properties for powder injection molding. A 3D printing filament was also obtained from a composition with 40% PEEK, which had good technological properties for FDM 3D printing. Products of satisfactory quality from suspensions with 50% PEEK can be produced by powder injection molding, but not by 3D printing. The selected compositions were used to obtain real PEEK products for practical applications.
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Emolaga, Carlo S., Persia Ada N. De Yro, Shaun Angelo C. Arañez, et al. "Void Content Measurement of the 3D Printed PEEK Materials by X-Ray Micro Computed Tomography." Diffusion Foundations and Materials Applications 31 (November 30, 2022): 29–35. http://dx.doi.org/10.4028/p-c00t77.
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Additive Manufacturing (AM) is revolutionizing the manufacturing industry as various AM technologies continue to mature and more AM-compatible materials are being developed. Polyether ether ketone (PEEK) is one of the promising materials at the forefront of this technological revolution as efforts to enhance its application as a 3D-printing material are continuously being pursued. In this study, the effect of printing parameters on the void content of 3D-printed PEEK was examined using a non-destructive method, X-ray micro computed tomography (X-ray micro-CT). Of the fused filament fabrication (FFF) parameters considered, higher nozzle temperature and printing speed were seen to promote an increase in void content while higher build plate temperature reduces it. Void content has a direct effect on the mechanical and other properties of the manufactured material and therefore provides a link between the printing parameters and the expected mechanical performance of these materials. This study also highlights the importance of choosing the right printing parameters to ensure the quality of the manufactured PEEK.
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Basgul, Cemile, Tony Yu, Daniel W. MacDonald, Ryan Siskey, Michele Marcolongo, and Steven M. Kurtz. "Structure–property relationships for 3D-printed PEEK intervertebral lumbar cages produced using fused filament fabrication." Journal of Materials Research 33, no. 14 (2018): 2040–51. http://dx.doi.org/10.1557/jmr.2018.178.
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Hasan, M. M. B., Ch Cherif, A. B. M. Foisal, T. Onggar, R. D. Hund, and A. Nocke. "Development of conductive coated Polyether ether ketone (PEEK) filament for structural health monitoring of composites." Composites Science and Technology 88 (November 2013): 76–83. http://dx.doi.org/10.1016/j.compscitech.2013.08.033.
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Wang, Yiqiao, Wolf-Dieter Müller, Adam Rumjahn, Franziska Schmidt, and Andreas Dominik Schwitalla. "Mechanical properties of fused filament fabricated PEEK for biomedical applications depending on additive manufacturing parameters." Journal of the Mechanical Behavior of Biomedical Materials 115 (March 2021): 104250. http://dx.doi.org/10.1016/j.jmbbm.2020.104250.
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Lancoš, Samuel, Miroslav Kohan, Marek Schnitzer, et al. "Methodology and Subsequent Analysis of Polymer Filament Production from PEEK Material With a Ceramic Admixture." Acta Mechanica Slovaca 26, no. 3 (2022): 14–21. http://dx.doi.org/10.21496/ams.2022.007.
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Subramani, Raja, Praveenkumar Vijayakumar, Maher Ali Rusho, Anil Kumar, Karthik Venkitaraman Shankar, and Arun Kumar Thirugnanasambandam. "Selection and Optimization of Carbon-Reinforced Polyether Ether Ketone Process Parameters in 3D Printing—A Rotating Component Application." Polymers 16, no. 10 (2024): 1443. http://dx.doi.org/10.3390/polym16101443.
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The selection of process parameters is crucial in 3D printing for product manufacturing. These parameters govern the operation of production machinery and influence the mechanical properties, production time, and other aspects of the final product. The optimal process parameter settings vary depending on the product and printing application. This study identifies the most suitable cluster of process parameters for producing rotating components, specifically impellers, using carbon-reinforced Polyether Ether Ketone (CF-PEEK) thermoplastic filament. A mathematical programming technique using a rating method was employed to select the appropriate process parameters. The research concludes that an infill density of 70%, a layer height of 0.15 mm, a printing speed of 60 mm/s, a platform temperature of 195 °C, an extruder temperature of 445 °C, and an extruder travel speed of 95 mm/s are optimal process parameters for manufacturing rotating components using carbon-reinforced PEEK material.
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Moiduddin, Khaja, Syed Hammad Mian, Sherif Mohammed Elseufy, Hisham Alkhalefah, Sundar Ramalingam, and Abdul Sayeed. "Polyether-Ether-Ketone (PEEK) and Its 3D-Printed Quantitate Assessment in Cranial Reconstruction." Journal of Functional Biomaterials 14, no. 8 (2023): 429. http://dx.doi.org/10.3390/jfb14080429.
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Three-dimensional (3D) printing, medical imaging, and implant design have all advanced significantly in recent years, and these developments may change how modern craniomaxillofacial surgeons use patient data to create tailored treatments. Polyether-ether-ketone (PEEK) is often seen as an attractive option over metal biomaterials in medical uses, but a solid PEEK implant often leads to poor osseointegration and clinical failure. Therefore, the objective of this study is to demonstrate the quantitative assessment of a custom porous PEEK implant for cranial reconstruction and to evaluate its fitting accuracy. The research proposes an efficient process for designing, fabricating, simulating, and inspecting a customized porous PEEK implant. In this study, a CT scan is utilized in conjunction with a mirrored reconstruction technique to produce a skull implant. In order to foster cell proliferation, the implant is modified into a porous structure. The implant’s strength and stability are examined using finite element analysis. Fused filament fabrication (FFF) is utilized to fabricate the porous PEEK implants, and 3D scanning is used to test its fitting accuracy. The results of the biomechanical analysis indicate that the highest stress observed was approximately 61.92 MPa, which is comparatively low when compared with the yield strength and tensile strength of the material. The implant fitting analysis demonstrates that the implant’s variance from the normal skull is less than 0.4436 mm, which is rather low given the delicate anatomy of the area. The results of the study demonstrate the implant’s endurance while also increasing the patient’s cosmetic value.
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Rajeshkumar Dhanapal, Vasudevan Alagumalai, Y. Justin Raj, Sundarakannan Rajendran, and Justin Sam George. "Enhancement of Mechanical and Wear Properties in 3D-printed PEEK Specimens using Eco-friendly Infill Patterns via Fused Filament Fabrication." Journal of Environmental Nanotechnology 13, no. 4 (2024): 332–40. https://doi.org/10.13074/jent.2024.12.2441105.
Full textAbstract:
The increasing use of 3D-printed PEEK materials in load-bearing applications necessitates a comprehensive evaluation of their wear characteristics and hardness under dynamic loading conditions. This study investigates the wear loss, coefficient of friction, and hardness values of PEEK materials with four distinct surface patterns: Line, Grid, Cubic, and Hexagon. Controlled experiments revealed that the Line and Hexagon patterns exhibited the lowest wear loss (0.004 grams), indicating superior wear resistance, while the Cubic pattern showed the highest wear loss (0.009 grams). In terms of friction, the Grid pattern demonstrated the lowest coefficient of friction (0.21), suggesting it offers the least resistance to movement, while the Line and Hexagon patterns had moderate coefficients of friction (0.40 and 0.35, respectively). The Cubic pattern displayed the highest coefficient of friction (0.45). Hardness testing revealed that the Hexagon pattern had the highest hardness value (30), followed by the Line pattern (28), the Grid pattern (25), and the Cubic pattern (20). These findings highlight the trade-offs between wear resistance, friction, and hardness among the different surface patterns, providing valuable insights for applications where these properties are crucial. SEM images were analyzed to investigate the wear characteristics of FFF-printed PEEK samples with varying infill patterns. The results showed that the Hexagon pattern exhibited the least surface degradation, demonstrating superior wear resistance compared to the Line, Cubic, and Grid patterns. This study offers valuable guidance for selecting optimal surface patterns in engineering and industrial applications to enhance performance and durability.