Screw extrusion-based additive manufacturing of PEEK

Jian Wei Tseng, Chao Yuan Liu, Yi Kuang Yen, Johannes Belkner, Tobias Bremicker, Bernard Haochih Liu, Ta Ju Sun, An Bang Wang

Research output: Contribution to journalArticlepeer-review

104 Citations (Scopus)

Abstract

Polyether-ether-ketone (PEEK) has high mechanical strength, thermal performance, and biocompatibility, and is widely used in biomedical and chemical engineering applications. However, to date there are no guidelines for the building of a 3D printer for highly viscous materials, e.g., PEEK. In this paper, a screw extrusion method was developed to overcome the existing problems of the filament-feeding method. Excellent flow stability (< 3% variation) and high printing speed (up to 370 mm/s) for PEEK printing were achieved. Highly reproducible mechanical tests of the printing products were demonstrated with 96% of the bulk material strength for the first time. Furthermore, an exchangeable printing head was built to cover both line- and plane-printing needs to widen its applications and improve printing surface quality (up to 0.945 nm in Ra). All printed material had a more brittle character in comparison with the bulk material and the post annealing process was found to have no significant effect on the mechanical strength. Additionally, porous artificial intervertebral cages with controllable size and distribution were manufactured to demonstrate potential applications.

Original languageEnglish
Pages (from-to)209-221
Number of pages13
JournalMaterials and Design
Volume140
DOIs
Publication statusPublished - 2018 Feb 15

All Science Journal Classification (ASJC) codes

  • General Materials Science
  • Mechanics of Materials
  • Mechanical Engineering

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