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Novel Low-Crystallinity Polyetheretherketone Copolymers for 3D Printing.

Azamat Zhansitov1, Zhanna Kurdanova1, Kamila Shakhmurzova1

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Synthesizing polyetheretherketone (PEEK) copolymers with 4,4'-dichlorodiphenylsulfone (DCDPS) improved FDM printing. Optimized DCDPS content balances processability and mechanical performance for high-quality PEEK parts.

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3D printing4,4′-dichlorodiphenylsulfonecopolymerscrystallizationmechanical propertiespolycondensationpolyetheretherketone

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Area of Science:

  • Polymer Chemistry
  • Materials Science
  • Additive Manufacturing

Background:

  • Polyetheretherketone (PEEK) is a high-performance thermoplastic with excellent mechanical and chemical properties.
  • Improving the processability and quality of PEEK parts in additive manufacturing (AM) remains a key challenge.

Purpose of the Study:

  • To synthesize PEEK copolymers with varying 4,4'-dichlorodiphenylsulfone (DCDPS) content.
  • To investigate the impact of DCDPS on thermophysical properties and mechanical performance.
  • To optimize PEEK copolymers for fused deposition modeling (FDM) printing.

Main Methods:

  • Synthesis of PEEK copolymers with controlled DCDPS content.
  • Differential scanning calorimetry (DSC) to analyze thermal properties (Tm, Tc, Tg, crystallinity).
  • Tensile testing to evaluate mechanical properties (strength, elastic modulus).
  • FDM printing trials to assess processability and part quality.

Main Results:

  • Increasing DCDPS content lowered melting temperature (Tm), crystallization temperature (Tc), and degree of crystallinity.
  • Glass transition temperature (Tg) increased with higher DCDPS content.
  • Structural amorphization led to decreased strength and elastic modulus, except at 15% DCDPS where chain rigidity increased.
  • PEEK copolymers with 5-20% DCDPS content enabled stable FDM printing without deformation or delamination.

Conclusions:

  • Tailoring DCDPS content in PEEK copolymers allows for fine-tuning of thermophysical and mechanical properties.
  • A DCDPS concentration of 15% offers an optimal balance, enhancing chain rigidity to counteract amorphization effects.
  • PEEK copolymers with 5-20% DCDPS are suitable for FDM printing, ensuring high-quality parts with improved processability and performance.