Carbon Fiber-reinforced Polyetheretherketone Research Articles

Bone healing under different lay-up configuration of carbon fiber-reinforced PEEK composite plates.

Secondary healing of fractured bones requires an application of an appropriate fixator. In general, steel or titanium devices are used mostly. However, in recent years, composite structures arise as an attractive alternative due to high strength to weight ratio and other advantages like, for example, radiolucency. According to Food and Drug Administration (FDA), the only unidirectionally reinforced composite allowed to be implanted in human bodies is carbon fiber (CF)-reinforced poly-ether-ether-ketone (PEEK). In this work, the healing process of long bone assembled with CF/PEEK plates with cross- and angle-ply lay-up configurations is studied in the framework of finite element method. The healing is simulated by making use of the mechanoregulation model basing on the Prendergast theory. Cells transformation is determined by the octahedral shear strain and interstitial fluid velocity. The process runs iteratively assuming single load cycle each day. The fracture is subjected to axial and transverse forces. In the computations, the Abaqus program is used. It is shown that the angle-ply lamination scheme of CF/PEEK composite seems to provide better conditions for the transformation of the soft callus into the bone tissue.

Pomegranate-like ZnMn2O4 nanospheres/carbon fiber network for interface enhancement structure-function PEEK composites with good electromagnetic interference shielding and thermal conductivity

The functionalization of structural carbon fiber reinforced polymer (CFRP) composites remains a significant challenge. In this work, the integration of structure-function was achieved in carbon fiber reinforced PEEK (CF/PEEK) composite by introducing a ZnMn2O4-based interface with the functionalities of electromagnetic interference (EMI) shielding and thermal conductivity (TC). The ZnMn2O4 nanospheres /CF network was constructed by introducing ZnMn2O4 nanospheres on the CF surface, realizing a significantly strengthened composite interface. Notably, the interlayer shear strength (ILSS) of the UCF-Z125/PEEK composite has reached 85.38 MPa, marking a 47.51% increase over the Unsized CF/PEEK composite. In addition, the EMI shielding and the TC performances of the CF/PEEK composite have also improved, with the EMI shielding of the composite enhanced by 54.67% and the through-plane TC increased by 47.17%. This structure-function integrated composite can be used not only as structural materials in aerospace applications but also as high-performance bifunctional materials in semiconductor and artificial intelligence industries.

Mechanical property of powder bed fusion printed carbon fiber reinforced polyetheretherketone and enhanced interlayer strength by post‐processing

AbstractAdditive Manufacturing (AM) of carbon fiber reinforced polyetheretherketone (CF/PEEK) composites with excellent performance by Powder Bed Fusion (PBF) has great potential in the applications where high strength and high service temperature are required. However, the reinforcement mechanisms of CF/PEEK composites based on the PBF process are complex and show significant differences from traditional processing methods. In this paper, the mechanical properties of CF/PEEK prepared by PBF were investigated. The results showed that its X‐axis tensile strength and modulus were approximately equal to or a bit lower than the theoretical value with randomly distributed CF, but much lower than the theoretical value with unidirectional distribution of CF in composites. Meanwhile, mechanical strength anisotropy was observed. The composites' Y‐axis tensile strength was slightly lower than X‐axis, and the lowest strength existed in Z‐axis. To improve the weak Z‐axis strength, post‐processing of annealing and solvent‐induced crystallization were carried out, and the Z‐axis tensile strength of post‐processed parts reached 50 MPa, which was 62% higher than untreated samples. Consequently, suitable CF and proper post‐ processing for AM of high strength CF/PEEK were proposed, which would promote the industrial application of this technology.Highlights The effect of CF on mechanical property of CF/PEEK prepared by PBF were studied. The optimal CF for PBF of high strength CF/PEEK were obtained. The post‐processing method for improving the Z‐axis strength were proposed. CF/PEEK with comprehensive mechanical property was successfully prepared by PBF.

Mechanical property of powder bed fusion printed carbon fiber reinforced polyetheretherketone and enhanced interlayer strength by post‐processing

AbstractAdditive Manufacturing (AM) of carbon fiber reinforced polyetheretherketone (CF/PEEK) composites with excellent performance by Powder Bed Fusion (PBF) has great potential in the applications where high strength and high service temperature are required. However, the reinforcement mechanisms of CF/PEEK composites based on the PBF process are complex and show significant differences from traditional processing methods. In this paper, the mechanical properties of CF/PEEK prepared by PBF were investigated. The results showed that its X‐axis tensile strength and modulus were approximately equal to or a bit lower than the theoretical value with randomly distributed CF, but much lower than the theoretical value with unidirectional distribution of CF in composites. Meanwhile, mechanical strength anisotropy was observed. The composites' Y‐axis tensile strength was slightly lower than X‐axis, and the lowest strength existed in Z‐axis. To improve the weak Z‐axis strength, post‐processing of annealing and solvent‐induced crystallization were carried out, and the Z‐axis tensile strength of post‐processed parts reached 50 MPa, which was 62% higher than untreated samples. Consequently, suitable CF and proper post‐ processing for AM of high strength CF/PEEK were proposed, which would promote the industrial application of this technology.Highlights The effect of CF on mechanical property of CF/PEEK prepared by PBF were studied. The optimal CF for PBF of high strength CF/PEEK were obtained. The post‐processing method for improving the Z‐axis strength were proposed. CF/PEEK with comprehensive mechanical property was successfully prepared by PBF.

CF/PEEK skins assembly by induction welding for thermoplastic composite sandwich panels

A method to assemble sandwich panels made of carbon fibre reinforced poly-ether-ether-ketone (CF/PEEK) facesheets and 3D-printed poly-ether-imide (PEI) honeycomb cores using induction welding is presented. Induction heating patterns inside CF/PEEK laminates of variable dimensions are first evaluated with a thermal camera and compared to a COMSOL Multiphysics model. Sandwich samples are then prepared by vacuum-assisted continuous induction welding under parameters selected from the modelling effort. Joining of sandwich panels made of CF/PEEK facesheets by induction welding under vacuum is demonstrated. Facesheets do not deconsolidate in the process and core crushing is avoided. Flatwise skin/core strength of the welded samples reaches up to 7 MPa, above reported performance for thermoset or thermoplastic composite sandwich panels.

Biomechanical Effects of Titanium and Carbon Fiber Reinforced PEEK as Dental Implant Material: A Finite Element Analysis.

The aim of this study is to examine the stresses on the peri-implant bone under occlusal forces of 30% Carbon fiber reinforced PEEK (Cfr-PEEK) and 60% Cfr-PEEK materials that can be used as an alternative to titanium dental implants by finite element analysis. Single-tooth implants of 30% Cfr-PEEK, 60% Cfr-PEEK and titanium were modeled in each of the maxillary anterior, maxilla posterior, mandibular posterior regions. As a result of the applied vertical and oblique forces; Von Misses stress, maximum principal stress and minimum principal stress values and stress distributions in the implant, cortical bone and spongious bone in each of the models were examined. 30% Cfr-PEEK implants stress in the surrounding bone was higher than titanium and 60% Cfr-PEEK implants. The 60% Cfr-PEEK material displayed lower stress distribution on both cortical and spongious peri-implant bone in all models. Titanium and 60% Cfr- PEEK implants exhibited biomechanically similar behavior and these implants conducted stresses to bone more homogeneous than the 30% Cfr-PEEK implants. Overall, oblique forces had more destructive effect than vertical forces and denser bone structure showed better stress distribution against incoming forces. For the routine use of Cfr-PEEK material as dental implant material; animal and long-term clinical studies are needed.

Emerging role of carbon fiber-reinforced polyetheretherketone instrumentation in spinal oncology: A systematic review

Spinal metastases are increasing in incidence with affected patients experiencing significant pain and disability. Continuous research and innovation in the field of spinal oncology have given rise to an increase in personalized treatment based on tumor characteristics and various patient-specific factors. Carbon fiber-reinforced polyetheretherketone (CFR-PEEK) instrumentation has gained popularity as an alternative to titanium-based implants primarily due to their ability to minimize imaging artifact. A literature search was performed to find articles that examined the use of CFR-PEEK screws in spinal fusion procedures in oncologic patients. Data from each study were compiled to compare complication rates, durability, and effects on postoperative imaging in patients treated with CFR-PEEK instrumentation to those treated with traditional titanium implants. Overall, CFR-PEEK-based products were similar to titanium hardware in terms of durability and complication rates while CFR-PEEK allows for improved postoperative tumor surveillance and radiosurgical planning.

Dental implant and abutment in PEEK: stress assessment in single crown retainers on anterior region.

Stress distribution assessment by finite elements analysis in poly(etheretherketone) (PEEK) implant and abutment as retainers of single crowns in the anterior region. Five 3D models were created, varying implant/abutment manufacturing materials: titanium (Ti), zirconia (Zr), pure PEEK (PEEKp), carbon fiber-reinforced PEEK (PEEKc), glass fiber-reinforced PEEK (PEEKg). A 50N load was applied 30o off-axis at the incisal edge of the upper central incisor. The Von Mises stress (σvM) was evaluated on abutment, implant/screw, and minimum principal stress (σmin) and maximum shear stress (τmax) for cortical and cancellous bone. The abutment σvM lowest stress was observed in PEEKp group, being 70% lower than Ti and 74% than Zr. On the implant, PEEKp reduced 68% compared to Ti and a 71% to Zr. In the abutment screws, an increase of at least 33% was found in PEEKc compared to Ti, and of at least 81% to Zr. For cortical bone, the highest τmax values were in the PEEKp group, and a slight increase in stress was observed compared to all PEEK groups with Ti and Zr. For σmin, the highest stress was found in the PEEKc. Stress increased at least 7% in cancellous bone for all PEEK groups. Abutments and implants made by PEEKc concentrate less σvM stress, transmitting greater stress to the cortical and medullary bone. The best stress distribution in PEEKc components may contribute to decreased stress shielding; in vitro and in vivo research is recommended to investigate this.

Strength-plasticity synergetic CF/PEEK composites obtained by adjusting melt flow rate

Short carbon fiber reinforced PEEK (CF/PEEK) composite materials with the advantages of excellent mechanical properties and easy processing, have been widely applied in the fields of aeronautics and astronautics, automotive engineering, and so on. However, their development in microinjection molding is hindered by the incompatibility between excellent plasticity and high mechanical properties. Herein, strength-plasticity synergetic CF/PEEK composites are prepared by adjusting the melt fluidity and crystallization behaviors, based on PEEK with different melt flow rate (MFR) and T800 carbon fiber. The rheological results showed that the melt viscosity of CF/PEEK composite was negatively related to the MFR of PEEK. Moreover, the mechanical properties of composites were increased by the crystallinity of PEEKs with high MFR. This work presents strength-plasticity synergetic CF/PEEK composites suitable for microinjection molding thin-walled and intricate components, offering new opportunities for next-generation portable electronic.

Performance parametric formulation of carbon fiber-reinforced composite locking bone implant plates based on finite-element analysis

The treatment of Giant Cell Tumor (GCT) in the distal radius poses challenges due to the intricate anatomical features of the bone. It often necessitates the use of long implant plates or the interconnection of multiple short plates after tumor excision. However, the deployment of metal plates may increase the risk of screw loosening and various complications. To address these challenges, this study proposes the adoption of carbon fiber-reinforced PEEK (CFRP) as the base material. As a unique strategy, performance parameters (PP) were developed to compare CFRP implant plates with a Ti-6Al-4V plate using the Finite-element Method. The focus was on four elements: the screw axial force, bone growth, callus formation, and bone resorption. The investigation into the screw axial force involved analyzing the internal force of the screw. The remaining parameters were evaluated using the stress, strain, or elastic energy induced in the bones. The findings showed that the second screw endured the largest screw axial force, measuring 10.16 N under a 90-degree 10-N loading at the translocated bone. The model without a callus exerted a significantly greater force on the screw than the model with a callus, leading to screw loosening in the early stage of treatment. The maximum PP, reached 1.62, was achieved with an angle-ply [456 /−456 ] laminate, featuring a weighting fraction of 0.7 for bone growth and 0.1 for the other parameters. This study provides a generalized methodology for assessing the performances of CFRP implants and offers guidelines for future development in composite implant plate technology.

Thermal-force coupling simulation of carbon fibre-reinforced poly-ether-ether-ketone thermoplastic composites during the laser-assisted automated tape placement process

To reveal the thermal-force coupling characteristics of the laser in-situ consolidation (ISC) of carbon fibre-reinforced poly-ether-ether-ketone (CF/PEEK) composites, a two-dimensional transient thermal-force model of CF/PEEK composites was constructed using COMSOL Multiphysics finite element simulation software to calculate the temperature history and the thermal stress variation of CF/PEEK composites during the laser-assisted automated tape placement (LATP) process. The results show that the temperature field formed on the surface of each layer by the laser spot during LATP is stable, and the temperature gradient at the front of the spot movement direction is higher than that at the back edge. The maximum stresses in the laminate occur on both sides of the first CF/PEEK layer and the stresses are unevenly distributed along the length and thickness directions of the lay-up. The composite material on both sides of the laminate tends to ‘shrink’ compared to its original position.

Investigation on grinding temperature characteristics of CF/PEEK and material removal mechanism under temperature treatments

Carbon fiber reinforced thermoplastic (CFRTP) composites grinding temperatures could even exceed the glass transition temperature (Tg) of the material due to heat accumulation, combined with the unknown material removal mechanism, resulting in machining defects. To investigate the grinding temperature distribution and maximum temperatures of carbon fiber-reinforced poly-ether-ether-ketone (CF/PEEK) composites, as a typical kind of CFRTP, an analytical temperature model considering the anisotropy was proposed based on the moving heat source theory, verified by the experimental results measured by the infrared camera. Further, the material removal mechanism under temperature treatments (below and above Tg) was also studied. In high temperatures (above Tg), there were many defects on surfaces after grinding, including resin smearing, severe deflection, fiber distortion, and grinding wheel clogging. Therefore, to reduce the grinding temperature below Tg, the vortex tube cooling-assisted grinding method was proposed in the research. The proposed method could reduce the grinding temperature in the grinding area, suppress resin smearing, improve the surface quality, enhance the elastic modulus and nano-hardness of the workpiece, and reduce the clogging of grinding wheels. This study provided a better understanding of the CF/PEEK grinding temperature characteristics and suggested a method to improve the grinding quality.

Inflammatory tissue response in human soft tissue is caused by a higher particle load near carbon fiber-reinforced PEEK compared to titanium plates

Titanium as the leading implant material in locked plating is challenged by polymers such as carbon fiber-reinforced polyetheretherketone (CFR-PEEK), which became the focus of interest of researchers and manufacturers in recent years. However, data on human tissue response to these new implant materials are rare.Osteosynthesis plates and peri‑implant soft tissue samples of 16 healed proximal humerus fractures were examined (n = 8 CFR-PEEK, n = 8 titanium). Soft tissue was analyzed by immunohistochemistry and µCT. The entrapped foreign bodies were further examined for their material composition by FTIR. To gain insight into their origin and formation mechanism, explanted and new plates were evaluated by SEM, EDX, profilometry and HR-CT.In the peri‑implant soft tissue of the CFR-PEEK plates, an inflammatory tissue reaction was detected. Tissues contained foreign bodies, which could be identified as tantalum wires, carbon fiber fragments and PEEK particles. Titanium particles were also found in the peri‑implant soft tissue of the titanium plates but showed a less intense surrounding tissue inflammation in immunohistochemistry. The surface of explanted CFR-PEEK plates was rougher and showed exposed and broken carbon fibers as well as protruding and deformed tantalum wires, especially in used screw holes, whereas scratches were identified on the titanium plate surfaces.Particles were present in the peri‑implant soft tissue neighboring both implant materials and could be clearly assigned to the plate material. Particles from both plate materials caused detectable tissue inflammation, with more inflammatory cells found in soft tissue over CFR-PEEK plates than over titanium plates. Statement of significanceOsteosynthesis plates are ubiquitously used in various medical specialties for the reconstruction of bone fractures and defects and are therefore indispensable for trauma surgeons, ENT specialists and many others. The leading implant material are metals such as titanium, but recently implants made of polymers such as carbon fiber-reinforced polyetheretherketone (CFR-PEEK) have become increasingly popular. However, little is known about human tissue reaction and particle generation related to these new implant types. To clarify this question, 16 osteosynthesis plates (n = 8 titanium and n = 8 CFR-PEEK) and the overlying soft tissue were analyzed regarding particle occurrence and tissue inflammation. Tissue inflammation is clinically relevant for the development of scar tissue, which is discussed to cause movement restrictions and thus contributes significantly to patient outcome.

Experimental investigation on effect of tool geometry on thermal and crystallization characteristics in drilling of carbon fiber reinforced PEEK composite

AbstractThis paper comprehensively investigated the effect of the tool geometries on heat transfer and special crystallization characteristics in the drilling of carbon fiber‐reinforced polyetheretherketone (CF/PEEK) composite for the first time. Three tools with different geometries (twist, brad, and dagger drill) are carried out on CF/PEEK drilling experiments, and temperature, as well as crystallinity and surface roughness, are introduced to make a comparative evaluation on the effect of the tool geometries. The results show that the drilling temperature is determined by the contact length of the profile between the drill and the material. Correspondingly, better surface quality with lower surface roughness and smoother surface is obtained by using a twist drill due to the heat‐induced PEEK smearing effect. Further, in situ XRD and differential scanning calorimeter (DSC) were used to characterize the crystallization characteristics where crystal phase transformation at different temperatures was measured. The occurring temperature of the strongest crystallization characteristics for CF/PEEK is basically not affected by tool geometries, all at 300°C, and the limiting crystallization temperature is 344.5 ± 0.7°C. The crystallinity is found to be affected by drilling temperature and cooling rate and gradually decreases along the heat transfer direction. This work provides a new sight into the improvement of CF/PEEK drilling.Highlights The effect of tool geometries on thermal and crystallization for CF/PEEK is provided. In situ XRD and DSC are used to characterize crystallization characteristics. The drilling temperature and cooling rate are both determinants of crystallinity. The limiting crystallization temperature of the CF/PEEK composite is 344.5 ± 0.7°C. Heat‐induced PEEK smearing effect improves the surface quality of CF/PEEK drilling.

Grinding performance investigation of multidirectional CF/PEEK composites—A comparative with unidirectional CF/PEEK

AbstractTo distinguish the grinding performance of the multidirectional (MD) and unidirectional (UD) carbon fiber‐reinforced thermoplastic (CFRTP) composites, MD and UD carbon fiber‐reinforced poly‐etherether‐ketone (CF/PEEK) composites were employed in this study. Different ply stacking sequences and process parameters were set for grinding experiments. Subsequently, the surface morphologies and roughness were observed and measured. Experimental results indicated that the variations of grinding forces with grinding parameters of MD‐CF/PEEK and UD‐CF/PEEK were consistent. However, the heat transfer mechanism and the effects of grinding parameters on the maximum grinding temperatures were different between the two composites. The grinding forces and temperatures of MD‐CF/PEEK were slightly lower than UD‐CF/PEEK, and MD‐CF/PEEK reached better surface quality under the same parameters, indicating that the grinding performance of MD‐CF/PEEK was not the simple superposition of UD‐CF/PEEK. In addition, the chip formation and material removal mechanism of CF/PEEK were investigated. The grinding performance of MD‐CF/PEEK was primarily dependent on the θ elements of laminate while the grinding performance of UD‐CF/PEEK was closely related to the fiber orientation angles during grinding. This study established a more in‐depth understanding into the grinding performance of MD‐CF/PEEK and provided technical guidance for high‐quality grinding of CFRTP.Highlights The grinding performance of the multidirectional (MD) and unidirectional (UD) carbon fiber‐reinforced poly‐etherether‐ketone (CF/PEEK) is compared. The grinding forces and temperatures of MD‐CF/PEEK are slightly lower than that of UD‐CF/PEEK, and the MD‐CF/PEEK reach a better surface quality under the same grinding parameters. The grinding performance of MD‐CF/PEEK is primarily dependent on the θ elements of laminate, and the change of layering order is not a critical factor. The grinding performance of UD‐CF/PEEK is closely related to the fiber orientation angles during the grinding process. The surface quality of MD‐CFRTP can be effectively improved by reducing the grinding depth and feed speed, and increasing the grinding wheel speed.

MIS technique for separation surgery in lumbar spine metastatic disease.

Around 40% of cancer patients present with spinal metastases (SM), the lumbar spine being the second most involved site (15%-30%) after the thoracic (60%-80%). Since the development of separation surgery, minimally invasive surgery (MIS) has increasingly been applied to approach SM, mirroring benefits yielded in the degenerative realm. Moreover, preoperative embolization potentially enhances local control for certain radioresistant histologies. Carbon fiber-reinforced PEEK hardware reduces image artifact, facilitating more accurate follow-up and radiotherapeutic planning. Additionally, short-segment cement-augmented constructs may be beneficial to decrease surgical morbidity and operative risk in this population. The authors present a lumbar spinal metastasis treated with MIS techniques. The video can be found here: https://stream.cadmore.media/r10.3171/2024.1.FOCVID23222.

Enhanced mechanical and tribological properties of 3D printed short carbon fiber reinforced polyether ether ketone composites

AbstractMaterial extrusion additive manufacturing provides an effective solution for fabrication of highly customized polyether ether ketone (PEEK) composite parts with any complex shape. Nevertheless, compared with conventional methods, the mechanical strength of 3D printed carbon fiber reinforced PEEK (CF/PEEK) composites is unsatisfactory due to the weak interface bonding strength and high voids content induced by the temperature difference. To overcome this challenge, a temperature‐control 3D printer was used to investigate the effects of ambient temperature and annealing temperature on the microstructure, crystallization behavior and mechanical properties of 3D printed parts. Moreover, the tribological properties of parts printed at different ambient temperature were also studied under various contact pressure. Experimental results showed that the ambient temperature and annealing treatment directly affected the interfacial bonding (fiber/matrix, filament/filament, layer/layer), crystallinity of printed samples, thus affecting their mechanical and tribological properties. The CF/PEEK parts printed at high ambient temperature of 200°C exhibited outstanding mechanical and tribological properties. This study has positive significance for promoting the application of 3D printed PEEK composites in the field of structural load‐bearing and friction materials.Highlights Structure–property relationships for 3D printed CF/PEEK composites. The ambient temperature strongly affects the thermal and microstructural properties Interaction between crystallization and molecular interface diffusion. Interfacial bonding and crystallinity determine the mechanical properties. Tribological properties are highly dependent on applied pressures.

Experimental Study on Tribological Properties of Coated Surface and Textured Surface under Seawater Lubrication Conditions

In order to improve the tribological properties of the flow distribution pair of the seawater axial piston pump, SAF2507 super duplex stainless steel and carbon-fiber-reinforced polyetheretherketone (CF/PEEK) were selected as the matching materials. The surface coating treatment and surface texture treatment were carried out on the flow distribution pair, and the friction and wear test were carried out by MMD-5A. In order to fully understand the friction and wear properties of the surface coating flow distribution pair and the surface texture flow distribution pair, and analyze the friction and wear mechanism, the data of the friction coefficient, wear loss, and wear surface morphology were obtained in the experiment. The results show that the coating surface has little difference in the test, the texture surface significantly reduces the friction coefficient, and the wear scar density is significantly reduced. Adding texture to the surface of the lower sample is better than adding it to the surface of the upper sample. The research results are helpful in improving the tribological performance of the flow distribution pair of the seawater axial piston pump.

Optical properties optimization of carbon fiber reinforced thermoplastic tapes by micro surface texturing for enhanced laser heating efficiency and in-situ consolidation quality during AFP process

The laser-assisted automated fiber placement (L-AFP) process of carbon fiber-reinforced thermoplastic composites suffers from insufficient heating efficiency and in-situ consolidation quality caused by significant reflection on the tape surface. Here, we propose a novel strategy to increase the heating efficiency by refocusing the reflected light, initially scattered to the environment and wasted, onto the tapes for multiple and full absorptions. The method for laser concentration is first validated through light-tracing simulation. Then, three kinds of tapes with different micro textures on the surface are prepared by the hot-embossing process. The transverse V-grooved texture tapes and flat surface tapes absorb 25% more laser energy than the longitudinal V-grooved and commercial tapes due to the reduction in transverse scattering angle from 180° to 2.72°. This leads to a temperature increase of 130 °C at the nip point during the L-AFP process at the lay-down rate of 500 mm/s with 1 kW laser power. Improved in-situ consolidation quality leads to a significant increase in the flexural and shear strength of L-AFP-prepared carbon fiber reinforced polyetheretherketone (CF/PEEK) laminates, with a reduction in porosity to around 2%.

Investigation of an Optimal Material Addition Rate for Energy Consumption and Dimensional Accuracy in Fused Filament Fabrication of CFR-PEEK.

The material addition rate (MAR) of fused filament fabrication (FFF) is an indicator of process efficiency varied by process parameter settings, which affects energy consumption and part quality in FFF. This study aims to identify the optimal MAR of FFF using carbon-fiber-reinforced polyether-ether-ketone (CFR-PEEK) by considering a trade-off between energy consumption and the dimensional accuracy of FFF outputs. A design of experiments considering two main process parameters is planned to print three sample types through FFF for CFR-PEEK. Then, the MAR (i.e., deposited material volume per build time) of FFF is obtained to derive individual regression models of energy consumption and the dimensional accuracy measured for each sample type. Furthermore, a trade-off between energy consumption and dimensional accuracy on the MAR is formulated to derive an optimal MAR for each sample type. The results show that FFF for CFR-PEEK has a trade-off between energy consumption and dimensional accuracy; there exists a specific MAR that maximizes the overall performance of energy consumption and dimensional accuracy for each sample type. The optimal MAR is the highest for the small volume sample, whereas it becomes the lowest for the vertical build orientation sample. This study suggests that the optimal MAR should be flexibly adjusted based on a fabricated part. The findings from this study also address the fact that decision-making for optimal FFF operations needs a transition from the identification of specific process parameter settings to the management of a proper process efficiency level in FFF.