Thermoplastic Extrusion Additive Manufacturing of High-Performance Carbon Fiber PEEK Lattices

Polyetheretherketone (PEEK) has been the focus of substantial additive manufacturing research for two principal reasons: (a) the mechanical performance approaches that of aluminum at relatively high temperatures for thermoplastics and (b) the potential for qualification in both the aerospace and bio...

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Bibliographic Details
Published inCrystals (Basel) Vol. 11; no. 12; p. 1453
Main Authors Santiago, Carolyn Carradero, Yelamanchi, Bharat, Diosdado De la Peña, Jose Angel, Lamb, Jeffrey, Roguski, Krzysztof, Turzyński, Filip, Faruqui, Ron, Choo, Kyosung, Du Plessis, Anton, Sillani, Francesco, MacDonald, Eric, Cortes, Pedro
Format Journal Article
LanguageEnglish
Published Basel MDPI AG 01.12.2021
Subjects
Additive manufacturing
Aerospace industry
Aluminum
Biomedical materials
Boundary conditions
Carbon fiber reinforced plastics
Carbon fibers
CF-PEEK
Computed tomography
Dimensional analysis
Extrusion
High temperature
high-temperature soluble support
Impact tests
Lattices
Manufacturing
Mechanical analysis
Mechanical properties
Medical imaging
Melting points
Plastic foam
Polyether ether ketones
Polymers
Powder beds
Raw materials
Simulation
Tensile strength
Thermal stability
thermoplastic extrusion
Thermoplastic resins
Yield stress
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Summary:Polyetheretherketone (PEEK) has been the focus of substantial additive manufacturing research for two principal reasons: (a) the mechanical performance approaches that of aluminum at relatively high temperatures for thermoplastics and (b) the potential for qualification in both the aerospace and biomedical industries. Although PEEK provides outstanding strength and thermal stability, printing can be difficult due to the high melting point. Recently, high-temperature soluble support has enabled the printing of lattices and stochastic foams with overhanging features in these high-performance carbon fiber thermoplastics, in which density can be optimized to strike a balance between weight and strength to enhance performance in applications such as custom implants or aerospace structures. Although polymer powder bed fusion has long been capable of the combination of these geometries and materials, material extrusion with high-temperature sacrificial support is dramatically less expensive. This research provides a comprehensive mechanical analysis and CT-scan-based dimensional study of carbon fiber PEEK lattice structures enabled with high-temperature support and including model validation.
ISSN:2073-4352
2073-4352
DOI:10.3390/cryst11121453