In-process laser heating for mechanical strength improvement of FFF-printed PEEK

Pu Han, Shams Torabnia, M. Faisal Riyad, Varunkumar Thippanna, Kenan Song, Keng Hsu

Research output: Contribution to journalArticlepeer-review

Abstract

Compared to conventional polymer manufacturing methods, additive manufacturing offers the distinct advantage of eliminating both tooling costs and lead time, rendering it an attractive solution for small batch production. Notably, fused filament fabrication (FFF), distinguished by its lack of resin or powder usage, exhibits the potential to operate effectively in vacuum and low-gravity environments. However, the inherent anisotropic strength of FFF components poses a significant constraint on its broader application. This study introduces a systematic exploration of a method designed to enhance the mechanical strength of 3D printed polyether ether ketone (PEEK) parts, approaching near isotropy through the implementation of an in-process laser heating system. PEEK, chosen for its remarkable strength and high-temperature tolerance, serves as the material. The essence of the laser-based approach lies in elevating the interface temperature for a slower cooling process, thereby allowing increased reptation and relaxation for improved mechanical strength. The application of this technology results in a substantial enhancement of the mechanical strength along the build direction for 3D-printed PEEK, surging from 18.8 MPa to an impressive 83.5 MPa. In addition, the mechanical strength along the in-plane direction experiences a commendable 9.5% increase, rising from 85.3 to 93.5 MPa. Although the difference in mechanical strength along the in-plane direction is modest (less than 10%), the strain before fracture exhibits a remarkable surge of 300%. Furthermore, the fracture behavior demonstrates significant variations. No significant improvement in crystallinity improvement with this technology is observed. The integration of this innovative technique emerges as a promising solution to overcome the limitations associated with utilizing FFF 3D printing in manufacturing production, showcasing the potential to revolutionize the mechanical properties of printed components.

Original languageEnglish (US)
JournalProgress in Additive Manufacturing
DOIs
StateAccepted/In press - 2024
Externally publishedYes

Keywords

  • Fused filament fabrication
  • Laser assisted
  • Mechanical strength
  • PEEK

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

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