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Additive Manufacturing of Functionally Graded Ceramic Materials by Stereolithography
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Advancements in Functionally Graded Polyether Ether Ketone Components: Design, Manufacturing, and Characterisation

Eric McNiffe1, Tobias Ritter1, Tom Higgins1

  • 1College of Science and Engineering, University of Galway, H91 TK33 Galway, Ireland.

Polymers
|July 29, 2023
PubMed
Summary
This summary is machine-generated.

This study optimized 3D printing for functionally graded polyether ether ketone (PEEK) components. High enclosure temperatures during printing significantly enhance material strength and interlayer bonding in PEEK parts.

Keywords:
3D printingPEEKadditive manufacturingfunctional graded materialsfused deposition modellingmaterial extrusion

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Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Polymer Engineering

Background:

  • Functionally Graded Materials (FGMs) offer advanced engineering solutions for metal and plastic components.
  • Polyether ether ketone (PEEK) is a high-performance thermoplastic suitable for demanding applications.
  • Optimizing additive manufacturing processes is crucial for realizing the potential of FGMs.

Purpose of the Study:

  • To develop and optimize a 3D printing methodology for producing functionally graded PEEK components.
  • To investigate the influence of printing parameters on the microstructure and properties of FGMs.
  • To characterize the porosity and interlayer bonding strength in 3D printed PEEK.

Main Methods:

  • Utilized a modified and optimized 3D printer for PEEK component manufacturing.
  • Employed scanning electron microscopy (SEM) to analyze bead interaction, porosity, and interlayer bonding.
  • Systematically varied process conditions, including enclosure temperature, during specimen fabrication.

Main Results:

  • Identified optimal printing parameters for creating FGMs with controlled microstructure.
  • Demonstrated that high enclosure temperatures significantly improve interlayer bond formation and part strength.
  • Observed increased crystallinity in PEEK specimens printed at elevated temperatures, correlating with enhanced mechanical properties.

Conclusions:

  • The developed 3D printing process enables the production of high-quality, functionally graded PEEK components.
  • Process parameter control, particularly enclosure temperature, is critical for achieving superior material properties.
  • This research advances the application of FGMs in additive manufacturing for enhanced engineering designs.