The Surface Characteristics, Microstructure and Mechanical Properties of PEEK Printed by Fused Deposition Modeling...

Additive manufacturing has gained attention for its ability to produce medical devices with customized geometries and mechanical properties. Prior research has shown that fused deposition modeling (FDM) can be used to fabricate medical-grade polymers like PEEK. However, the impact of printing parameters on the final product's characteristics remains unclear. This gap motivated a closer examination of how FDM settings influence the mechanical and structural properties of PEEK. No prior work had resolved how raster angle specifically affects performance. The study aimed to address this uncertainty by analyzing surface, microstructural, and mechanical changes in printed PEEK. It was already known that FDM can alter polymer behavior, but the extent and nature of these changes were not fully understood. The researchers propose that raster angle plays a key role in determining mechanical strength. This study builds on prior findings by providing a more detailed analysis of how printing parameters influence PEEK performance.

The purpose of the study was to evaluate how fused deposition modeling (FDM) affects the surface characteristics, microstructure, and mechanical properties of polyether-ether-ketone (PEEK). The researchers aimed to determine whether raster angle influences mechanical strength and failure mechanisms in printed PEEK. They also sought to identify optimal printing parameters for improved performance. The study focused on understanding how FDM alters PEEK's behavior compared to traditional manufacturing methods. The motivation came from the need to improve the reliability and performance of 3D-printed medical devices. The researchers propose that raster angle is a critical variable in controlling mechanical outcomes. This work builds on prior studies by examining the relationship between printing settings and material behavior. The goal was to provide practical guidelines for using FDM to produce PEEK-based orthopedic implants.

The study used fused deposition modeling (FDM) to fabricate polyether-ether-ketone (PEEK) samples with varying raster angles. Surface characteristics were analyzed using contact angle measurements and surface hardness tests. Microstructural changes were assessed through thermal and crystallographic analysis. Mechanical properties were evaluated via tensile, flexural, and shear strength tests. The researchers compared results across different raster angles to identify trends. They also examined failure mechanisms using imaging and structural analysis. The study focused on how raster orientation affects mechanical performance. The researchers propose that raster angle influences strength but not failure mode. This approach allowed them to isolate the effects of printing parameters on material behavior.

The study found that raster angle significantly affects the mechanical strength of FDM-printed PEEK. Horizontal infill with a 30° raster angle showed the highest tensile, flexural, and shear strengths at (76.5 ± 1.4) MPa, (149.7 ± 3.0) MPa, and (55.5 ± 1.8) MPa, respectively. Surface hardness decreased in printed samples compared to the original material. The surface became more hydrophilic, as indicated by lower contact angles. The crystal unit cell and thermal properties remained unchanged during printing. Failure mechanisms were linked to internal voids rather than material properties. The researchers propose that raster angle influences strength but not failure type. These findings suggest that optimizing raster angle can improve the mechanical performance of FDM-printed PEEK.

The authors conclude that raster angle significantly influences the mechanical strength of FDM-printed PEEK. Horizontal infill with a 30° raster angle offers the best mechanical performance. The surface becomes more hydrophilic and less hard after printing. The failure mechanism is primarily due to internal voids rather than material properties. The crystal structure and thermal attributes remain unchanged during the printing process. The researchers propose that raster angle is a key factor in determining mechanical outcomes. These findings provide guidelines for optimizing FDM parameters in PEEK-based medical applications. The study supports the use of FDM for orthopedic implants by identifying optimal printing settings.