Design and development of an open-source high-temperature FFF 3D printer for high-performance polymers

Area of Science:

• Additive Manufacturing
• Materials Science
• Polymer Engineering

Background:

• High-performance polymers (e.g., PEI, PEEK) offer superior properties for demanding applications.
• Existing commercial systems for these polymers are expensive and lack modularity.
• High printing temperatures (up to 450°C nozzle, 150°C chamber) pose significant fabrication challenges.

Purpose of the Study:

• To design and construct an open-source, high-temperature FFF 3D printer for high-performance polymers.
• To create a modular, user-friendly, and cost-effective alternative to commercial systems.
• To enable easier fabrication of advanced polymer components for various industries.

Main Methods:

• Designed and built an open-source FFF 3D printer using readily available components.
• Utilized a Duet3D motherboard with RepRap firmware for high customizability.
• Incorporated an aluminum T-slot frame for sensor integration and process monitoring.
• The printer supports up to 500°C nozzle, 200°C bed, and 120°C chamber temperatures.

Main Results:

• Successfully fabricated components using ULTEM 1010, ULTEM 9085, and PEEK.
• Validated printer performance through printing and dimensional analysis of ULTEM 1010 calibration cubes.
• Demonstrated accuracy, precision, and repeatability of the developed 3D printing system.

Conclusions:

• The developed open-source 3D printer effectively fabricates high-performance polymers.
• The modular design allows for customization and integration of advanced monitoring.
• This system provides a more accessible and adaptable solution for high-temperature polymer additive manufacturing.