Additive manufacturing of high‐performance engineering polymers: present and future

Abstract

High‐performance engineering polymers continually challenge existing boundaries of rapidly emerging research areas including electronics, transportation, energy, defense and aerospace. Significant research attention over the past decade highlights the exceptional performance of these polymers due to their superior thermomechanical properties and stability under extreme conditions. Unfortunately, inherent structure–property relationships of high‐performance engineering polymers, which predict this unique complement of physical properties, also describe high‐viscosity melts and high melting temperatures. These processing challenges have steered researchers towards advanced processing methods, such as additive manufacturing, that allow for unprecedented control over part geometry. In addition, additive manufacturing serves to advance application–cost relationships, as part optimization and 3D printing of previous monolithic components allow for less material consumption. Currently, the additive manufacturing materials toolbox only contains a fraction of commercially available high‐performance polymers due to unique processing constraints. This review discusses recent efforts towards the successful additive manufacturing of three high‐performance polymer families, i.e. polysulfones, poly(ether ether ketone)s and polyimides. © 2021 Society of Industrial Chemistry.

Self-Monitoring Performance of 3D-Printed Poly-Ether-Ether-Ketone Carbon Nanotube Composites

“…Among the vast universe of polymer 3D printing, the AM of polymers with superior mechanical, physical and chemical properties, such as so-called high-performance polymers (polyether-ether-ketone PEEK, polyether-ketone-ketone PEKK, polyether-ketone-ether-ketone PEKEK, polyether-imide PEI, etc. ), is becoming predominant in many engineering applications in the aerospace, automotive and biomedical sectors [ 7 , 8 , 9 , 10 ]. Fused filament fabrication (FFF) is, in most cases, the only 3D-printing technique suitable for the additive manufacturing of these materials, and the recent literature has made it clear that the mechanical properties, performance and failure mode of the printed parts are highly dependent on many process parameters (such as the layout, orientation, infill, parameters, etc.)…”

Recent Progress in Research of Additive Manufacturing for Polymers

“…Additive manufacturing (AM) methods have grown and evolved rapidly in recent years. AM for polymers is particularly exciting and has great potential in transformative and translational research in many fields, such as biomedical [ 1 , 2 , 3 ], aerospace [ 4 , 5 ], and electronics [ 6 , 7 ]. Current methods for polymer AM include material extrusion, material jetting, vat photopolymerization, and powder bed fusion.…”

Nurturing inclusivity: removing obstacles and valuing perspectives

“…Long and Weyhrich summarize recent advances in the design of engineering polymers for a diversity of printing modalities, and the article summarizes recent efforts but also points to opportunities for the redesign of engineering polymers for additive manufacturing with an eye on sustainability. 10 Goyal and Cochran further highlight the importance of engineering polymer design and corresponding composites, where interfacial adhesion between the matrix and the additive play an integral role in dictating ultimate mechanical performance. 11 Song and coworkers reinforce the importance of emerging manufacturing processes and fiber formation for the design of composites with microstructural control.…”

“…Engineering polymers play a critical role in the design of next generation electric vehicles and materials for harsh environments for alternate energy and space exploration. Long and Weyhrich summarize recent advances in the design of engineering polymers for a diversity of printing modalities, and the article summarizes recent efforts but also points to opportunities for the redesign of engineering polymers for additive manufacturing with an eye on sustainability 10 . Goyal and Cochran further highlight the importance of engineering polymer design and corresponding composites , where interfacial adhesion between the matrix and the additive play an integral role in dictating ultimate mechanical performance 11 .…”