Comprehensive analysis of fused deposition modeling process conditions for enhancing mechanical properties and surface quality of 3D-Printed poly-ether-ether-ketone

Abstract

Fused deposition modeling (FDM) technology is a convenient manufacturing approach for poly-ether-ether-ketone (PEEK) components. In this study, a comprehensive study of the influence of FDM process parameters on the mechanical property and surface quality of 3D-printed PEEK printed with different directions was carried out. The results show that crystallinity of PEEK materials and the pores/gaps between the printing filaments jointly affect the mechanical properties and surface quality of PEEK structural parts. Then, material-structure-property linkage mechanism was revealed. Through the research conducted, crucial processing parameters to enhance the mechanical properties and surface quality of PEEK samples was determined. High tensile strength (91.75 MPa, which was close to the performance of injection molded components) and surface quality (Ra 7.9 μm) was obtained by regulation the nozzle temperature and annealing temperature to improve the crystallinity. Meanwhile, tensile strength of z-Sample was increased from 7.36 MPa to 18.30 MPa (with an increase of 148.64%). High Young's modulus (3.09 GPa) and large plastic strain (exceed 13.91%) was achieved by regulation the nozzle temperature and printing speed to reduce the porosity between PEEK filaments.