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<p>Polyether-ether-ketone (PEEK) is a high-performance thermoplastic widely processed using fused filament fabrication (FFF) for applications requiring high mechanical strength and thermal stability. However, the high extrusion temperatures and melt viscosity required for PEEK printing make it challenging to produce defect-free parts with robust mechanical properties using FFF. In addition, the temperature differential that occurs during the FFF creates internal stress that results in stringing, delamination, under and over extrusion, and other issues that affect the quality of the formed sample. In order to reduce internal voids and improve tensile and compressive strength, this study assessed the impact of varying nozzle diameters (0.4, 0.6, and 0.8&#xa0;mm) on other crucial process variables like extrusion temperature (370, 420, and 470&#xa0;°C) and deposition speed (20, 40, and 60&#xa0;mm/s) on FFF based on PEEK printing. The Complex Proportional Assessment (COPRAS) technique and ANOVA analysis was used to look at the influence of independent variables and the associated combined impact of parameters. At an extrusion temperature of 470&#xa0;°C and an optimal deposition speed of 40&#xa0;mm/s, using a 0.4&#xa0;mm nozzle significantly suppresses defect formation, increasing tensile strength from 67.52&#xa0;MPa to 96.2&#xa0;MPa and compressive strength from 98.51&#xa0;MPa to and 124.32&#xa0;MPa, respectively. The goal of this study is to support the fabrication of high-quality, application-specific PEEK components by identifying optimized high-temperature FFF process parameters that enhance mechanical performance and reduce defects.</p>

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Synergetic parametric impact of nozzle diameter with extrusion temperature and speed to achieve the defect-free interlayer bonding of FFF based PEEK parts

  • 期刊论文

  • 发表日期：

    2026年1月23日

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  • Khaja Moiduddin,
  • Saravana Kumar Murugesan,
  • Che-Hua Yang,
  • Syed Hammad Mian,
  • Usama Umer

摘要

Polyether-ether-ketone (PEEK) is a high-performance thermoplastic widely processed using fused filament fabrication (FFF) for applications requiring high mechanical strength and thermal stability. However, the high extrusion temperatures and melt viscosity required for PEEK printing make it challenging to produce defect-free parts with robust mechanical properties using FFF. In addition, the temperature differential that occurs during the FFF creates internal stress that results in stringing, delamination, under and over extrusion, and other issues that affect the quality of the formed sample. In order to reduce internal voids and improve tensile and compressive strength, this study assessed the impact of varying nozzle diameters (0.4, 0.6, and 0.8 mm) on other crucial process variables like extrusion temperature (370, 420, and 470 °C) and deposition speed (20, 40, and 60 mm/s) on FFF based on PEEK printing. The Complex Proportional Assessment (COPRAS) technique and ANOVA analysis was used to look at the influence of independent variables and the associated combined impact of parameters. At an extrusion temperature of 470 °C and an optimal deposition speed of 40 mm/s, using a 0.4 mm nozzle significantly suppresses defect formation, increasing tensile strength from 67.52 MPa to 96.2 MPa and compressive strength from 98.51 MPa to and 124.32 MPa, respectively. The goal of this study is to support the fabrication of high-quality, application-specific PEEK components by identifying optimized high-temperature FFF process parameters that enhance mechanical performance and reduce defects.