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

Various commercial systems have been developed for printing high-performance polymers such as polyetherimide (PEI) and polyetheretherketone (PEEK) for use in medical, aerospace, automotive, and electrical components.High-performance polymers offer improved chemical resistance, thermal resistance, and mechanical properties compared to commonly used FFF materials such as PLA, PETG, and ABS. However, high-performance polymers are difficult to print due to the high printing temperatures required, such as nozzle temperatures up to 450°C, chamber temperature of 150°C, and bed temperatures up to 170°C. Most commercial systems capable of fabricating these materials are cost-prohibitive and lack modularity for user customization or modifications. An open-source, high-temperature FFF 3D printer was designed and constructed for high-performance polymers to be easily constructed, highly modular, and user-friendly. The printer was built using readily available components and controlled with a Duet3D motherboard running RepRap firmware to be highly customizable. The frame was built with aluminum T-slot channels to allow for integration with sensors, such as additional thermocouples or cameras for robust process monitoring. The printer can accommodate a 500°C nozzle, 200°C bed, and 120°C chamber. The system was validated through successful fabrication of ULTEM 1010, ULTEM 9085, and PEEK components. Performance was evaluated using three ULTEM 1010 calibration cubes printed under optimized process parameters. Dimensional measurements were used to assess accuracy, precision, and repeatability of the printer.