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<p>Additive manufacturing (AM) is an innovative technology widely used in several sectors, including aerospace, electronics, automotive and medical. One of the processes used is deposition of molten filaments using a material. In this study, Poly (ether ether ketone) was used as the base material for additive manufacturing via the fused deposition modeling (FFF) process. The main objective of this study was to investigate how variations in nozzle temperature, layer thickness, and printing speed influence mechanical properties and porosity, with a focus on the Z-direction, which is particularly prone to weak interlayer bonding. By systematically analyzing these effects, the study provides new insights into optimizing FDM process parameters to improve interlayer adhesion and the overall structural integrity of vertically printed components. In addition, we carried out characterization using and X-ray diffraction analyses dynamic mechanical analysis (DMA) and scanning electron microscopy (SEM). Using Response Surface Methodology (RSM), optimal printing conditions were predicted as 405&#xa0;°C nozzle temperature, 60&#xa0;mm/s printing speed, and 0.1&#xa0;mm layer thickness, yielding components with a Young’s modulus of 3302&#xa0;MPa, tensile strength of 72&#xa0;MPa, strain at break of 3.25%, and a porosity rate of 4.70%, closely matching the experimental observations. These results may indicate that the optimized printing conditions predicted by RSM can reliably produce PEEK components with balanced mechanical performance and low porosity.</p>

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Investigating the effect of printing parameters on the porosity and tensile behavior of 3D-printed PEEK in Z-direction

  • 期刊论文

  • 发表日期：

    2026年5月27日

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  • Anouar El Magri,
  • Zakariae Bouchkara,
  • Sebastien Vaudreuil,
  • Hamid Reza Vanaei

摘要

Additive manufacturing (AM) is an innovative technology widely used in several sectors, including aerospace, electronics, automotive and medical. One of the processes used is deposition of molten filaments using a material. In this study, Poly (ether ether ketone) was used as the base material for additive manufacturing via the fused deposition modeling (FFF) process. The main objective of this study was to investigate how variations in nozzle temperature, layer thickness, and printing speed influence mechanical properties and porosity, with a focus on the Z-direction, which is particularly prone to weak interlayer bonding. By systematically analyzing these effects, the study provides new insights into optimizing FDM process parameters to improve interlayer adhesion and the overall structural integrity of vertically printed components. In addition, we carried out characterization using and X-ray diffraction analyses dynamic mechanical analysis (DMA) and scanning electron microscopy (SEM). Using Response Surface Methodology (RSM), optimal printing conditions were predicted as 405 °C nozzle temperature, 60 mm/s printing speed, and 0.1 mm layer thickness, yielding components with a Young’s modulus of 3302 MPa, tensile strength of 72 MPa, strain at break of 3.25%, and a porosity rate of 4.70%, closely matching the experimental observations. These results may indicate that the optimized printing conditions predicted by RSM can reliably produce PEEK components with balanced mechanical performance and low porosity.