TY - JOUR
T1 - In-process laser heating for mechanical strength improvement of FFF-printed PEEK
AU - Han, Pu
AU - Torabnia, Shams
AU - Riyad, M. Faisal
AU - Thippanna, Varunkumar
AU - Song, Kenan
AU - Hsu, Keng
N1 - Publisher Copyright:
© The Author(s), under exclusive licence to Springer Nature Switzerland AG 2024.
PY - 2024
Y1 - 2024
N2 - 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.
AB - 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.
KW - Fused filament fabrication
KW - Laser assisted
KW - Mechanical strength
KW - PEEK
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U2 - 10.1007/s40964-024-00833-4
DO - 10.1007/s40964-024-00833-4
M3 - Article
AN - SCOPUS:85207570645
SN - 2363-9512
JO - Progress in Additive Manufacturing
JF - Progress in Additive Manufacturing
ER -