Optimization of printing parameters for improvement of mechanical and thermal performances of 3D printed poly(ether ether ketone) parts

Abstract Many processing parameters can be adjusted to optimize the fused filament fabrication (FFF) process, a popular and widely used additive manufacturing techniques for plastic materials. Among those easily adjusted parameters are the nozzle temperature, printing speed, raster orientation, and layer thicknesses. Using poly(ether ether ketone) (PEEK) as the base material, a design of experiments analysis was performed on the main FFF parameters. A response surface methodology was applied to analyze the results and to maximize the output responses. Results have shown that the nozzle temperature is the most influential parameter on tensile properties and the crystallinity degree of printed PEEK by FFF process. Parts produced with optimized FFF parameters were then subjected to an annealing treatment to induce a relaxation of residual stress and to enhance crystallinity. The best properties for 3D printed PEEK parts were achieved with annealed parts prepared at 400°C with a printing speed of 30 mm/s, 0.15 mm layer thickness and raster orientation of [0°/15°/−15°]. The resulting parts have mechanical properties comparable to those of injected PEEK.