Current understanding and challenges in high temperature additive manufacturing of engineering thermoplastic polymers

Das, Arit; Chatham, Camden A.; Fallon, Jacob J.; Zawaski, Callie E.; Gilmer, Eric L.; Williams, Christopher B.; Bortner, Michael J.

doi:10.1016/j.addma.2020.101218

Cited by 113 publications

(94 citation statements)

References 120 publications

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“…[175] PEK has a higher melting point than PEEK at ≈370 °C, and sintered PEK specimens exhibit a higher service temperature, tensile modulus and strength than PEEK specimens. [176] PEK demonstrates a high load-bearing capacity and excellent chemical resistance and thermal stability, which makes it very suitable for automotive, aerospace, and aeronautical applications. The mechanical properties of sintered PEK specimens could approach those of injection-molded specimens, and near-fully dense specimens with excellent thermal and mechanical properties that vary minimally with their build positions could be fabricated.…”

Section: (28 Of 54)mentioning

confidence: 99%

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Recent Progress on Polymer Materials for Additive Manufacturing

Tan

Zhu

Zhou

2020

Adv Funct Materials

488

238

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Additive manufacturing (AM) is the process of printing 3D objects in a layer-by-layer manner. Polymers and their composites are some of the most widely used materials in modern industries and are of great interest in the field of AM due to their vast potential for various applications, especially in the medical, aerospace, and automotive industries. Many studies have been conducted to develop new polymer materials for AM techniques, which include vat photopolymerization, material jetting, powder bed fusion, material extrusion, binder jetting, and sheet lamination. Although several reviews on the development of polymer materials for AM have been published, most of them only focus on a specific application, process, or type of material. Therefore, this article serves to provide a comprehensive review on the progress in polymer material development for AM techniques. It begins with an introduction to different AM techniques, followed by highlighting the progress of their development. Material requirements, notable advances in newly developed materials and their potential applications are discussed in detail and summarized. This review concludes by identifying the major challenges currently encountered in using AM for polymer materials and providing insights into the valuable opportunities it presents, in hopes of spurring further development in this field.

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Section: (28 Of 54)mentioning

confidence: 99%

“…Owing to its excellent properties, PEKK is extremely popular for aerospace applications. Although it is challenging to process PEKK due to its high melting point, its low shrinkage (30% lower than PA12) [ 171b ] and potentially high powder reusability rate [ 176 ] make it a promising high‐performance material for SLS.…”

Section: Thermoplastic Powdersmentioning

confidence: 99%

Recent Progress on Polymer Materials for Additive Manufacturing

Tan

Zhu

Zhou

2020

Adv Funct Materials

488

238

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“…Aniwaa, for example, lists 7 high-temperature 3-D printers commercially available in 2020 with prices that range from $25,000 to $110,000 with most costing over $50,000 [54] ). High-costs of such high-temperature printers exists because of the challenges of printing above 250 °C [55] . Previous attempts to reduce the costs of high-temperature 3-D printer have used retrofits of existing systems.…”

Section: Hardware In Contextmentioning

confidence: 99%

Open source high-temperature RepRap for 3-D printing heat-sterilizable PPE and other applications

Skrzypczak¹,

Tanikella²,

Pearce³

2020

HardwareX

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“…Several studies have reported that further postprocessing procedures such as annealing [ 28 , 32 ] could eliminate the dark amorphous regions caused due to irregular crystallization in PEEK parts. Figure 10 d,e illustrates a PSI, before and after annealing postprocessing procedure.…”

Section: Discussionmentioning

confidence: 99%

Quality Characteristics and Clinical Relevance of In-House 3D-Printed Customized Polyetheretherketone (PEEK) Implants for Craniofacial Reconstruction

Sharma

Aghlmandi

Cao

et al. 2020

JCM

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Additive manufacturing (AM) of patient-specific implants (PSIs) is gradually moving towards in-house or point-of-care (POC) manufacturing. Polyetheretherketone (PEEK) has been used in cranioplasty cases as a reliable alternative to other alloplastic materials. As only a few fused filament fabrication (FFF) printers are suitable for in-house manufacturing, the quality characteristics of the implants fabricated by FFF technology are still under investigated. This paper aimed to investigate PEEK PSIs fabricated in-house for craniofacial reconstruction, discussing the key challenges during the FFF printing process. Two exemplary cases of class III (Group 1) and class IV (Group 2) craniofacial defects were selected for the fabrication of PEEK PSIs. Taguchi’s L9 orthogonal array was selected for the following nonthermal printing process parameters, i.e., layer thickness, infill rate, number of shells, and infill pattern, and an assessment of the dimensional accuracy of the fabricated implants was made. The root mean square (RMS) values revealed higher deviations in Group 1 PSIs (0.790 mm) compared to Group 2 PSIs (0.241 mm). Horizontal lines, or the characteristic FFF stair-stepping effect, were more perceptible across the surface of Group 1 PSIs. Although Group 2 PSIs revealed no discoloration, Group 1 PSIs displayed different zones of crystallinity. These results suggest that the dimensional accuracy of PSIs were within the clinically acceptable range; however, attention must be paid towards a requirement of optimum thermal management during the printing process to fabricate implants of uniform crystallinity.

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Current understanding and challenges in high temperature additive manufacturing of engineering thermoplastic polymers

Cited by 113 publications

References 120 publications

Recent Progress on Polymer Materials for Additive Manufacturing

Recent Progress on Polymer Materials for Additive Manufacturing

Open source high-temperature RepRap for 3-D printing heat-sterilizable PPE and other applications

Quality Characteristics and Clinical Relevance of In-House 3D-Printed Customized Polyetheretherketone (PEEK) Implants for Craniofacial Reconstruction

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