Polyetheretherketone (PEEK)/polyetherimide (PEI) blends (50/50, v/v) keeping the crystal phase of PEEK have been manufactured by alternate PEEK/PEI layer stacking. This strategy avoided the complete miscibility of both polymers, keeping layers of PEEK and PEI unmixed along the sample thickness, as well as promoting the formation of a smooth interfacial layer where PEEK and PEI were mixed. The properties of this interface after processing at molten state and different times was studied by DSC, DMA, and X-Ray synchrotron. These techniques allowed monitoring the evolution of glass transition, where isolated Tg’s for both pristine polymers were observed even after long processing time. PEEK crystallinity slightly decreased during manufacturing, whereas PEEK crystal parameters did not vary. These observations show that, although the interface—the zone where both polymers are mixed—grew, layers with pristine polymers remained even after prolonged processing time. The preservation of the PEEK crystallinity was also observed in the mechanical properties of the multilayer PEEK/PEI films, which were compared with pristine PEEK and PEI films. Multilayer samples processed for shorter times rendered higher young modulus, tensile strength, and strain at break.

Current studies on nanocomposites have focused on their multifunctional properties and their industrial production. In this work, polyetheretherketone (PEEK)/graphene nanoplate (GNP) composites were produced by a direct semi-industrial process. Different percentages of untreated GNP (1, 5, and 10 wt.%) were added to PEEK by employing melt-compounding followed by injection-moulding. Despite the semi-industrial approach used, the modulus, strength, and Poisson coefficient of the nanocomposites (1 and 5 wt.%) were not significantly affected by the addition of GNP. However, there was a slight decrease in the strength at 10 wt.% GNP. Our study also shows that the thermal conductivities of PEEK/GNP composites are up to 2.5 times higher than that of pure PEEK.