Improvement of tensile and flexural properties of 3D printed PEEK through the increase of interfacial adhesion

Rendas, Pedro; Figueiredo, Lígia; Geraldo, Madalena; Vidal, Catarina; Soares, Bruno

doi:10.1016/j.jmapro.2023.03.024

Cited by 21 publications

(15 citation statements)

References 38 publications

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“…Tensile test specimens were designed and dimensioned following the specifications from ASTM D638 [ 48 ] for specimen type IV, as illustrated in Figure 1 . The G-code printing file was generated using the software Simplify3D (v4.1.2, Simplify3D, Blue Ash, OH, USA) with the specimen built flat on the print bed, and the printing parameters were selected based on parameter optimisation results for tensile strength from a previous work [ 46 ]. Additionally, to avoid discontinuities in the cross-section reduction area of the specimen with the rectilinear deposition ( Figure 2 a), the concentric deposition strategy was used, which is a pattern that also aligns the deposited lines with the specimen tensile loading ( Figure 2 b).…”

Section: Methodsmentioning

confidence: 99%

“…Fatigue tests were performed on the 3D-printed PEEK specimens under load-controlled conditions for three different stress levels. For each level, the maximum stress applied (

) corresponded to 75%, 85%, and 95% of the tensile strength of 86.7 MPa that was previously determined using similar 3D-printed PEEK specimens [ 46 ]. Moreover, a representative engineering stress–strain curve obtained in a monotonic tensile test is provided in Figure 3 [ 46 ], where it can be seen that the tensile strength is almost coincident with the yield stress for PEEK, as in accordance with the ASTM D638 standard.…”

Section: Methodsmentioning

confidence: 99%

“…In this work, the high-cycle fatigue behaviour of 3D-printed PEEK is documented. PEEK specimens were printed using optimal parameters obtained in previous works [ 46 ] and tested under tension–tension cyclic loading with different stress levels concerning the tensile strength of printed specimens. With this, the S-N (Stress-Life/Number of cycles) curve fitting the experimental data is plotted to document 3D-printed PEEK’s fatigue behaviour, and the fracture surfaces of specimens that failed under different stress levels were analysed to better understand the failure mechanisms involved.…”

Section: Introductionmentioning

confidence: 99%

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High-Cycle Fatigue Behaviour of Polyetheretherketone (PEEK) Produced by Additive Manufacturing

Rendas,

Imperadeiro,

Martins

et al. 2023

Polymers

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Polyetheretherketone (PEEK) is the leading high-performance thermoplastic biomaterial that can be processed through material extrusion (ME) additive manufacturing (AM), also known as three-dimensional (3D) printing, for patient-specific load-bearing implant manufacture. Considering the importance of cyclic loading for load-bearing implant design, this work addresses the high-cycle fatigue behaviour of 3D-printed PEEK. In this work, printed PEEK specimens are cyclically loaded under stress-controlled tension–tension using different stress levels between 75% and 95% of printed PEEK’s tensile strength. The experimental results are used to document 3D-printed PEEK’s fatigue behaviour using Basquin’s power law, which was compared with previous fatigue research on bulk PEEK and other 3D-printing materials. As a pioneering study on its fatigue behaviour, the results from this work show that 3D-printed PEEK exhibits an above-average fatigue strength of 65 MPa, corresponding to about 75% of its tensile strength. Fracture surface analysis suggests that a transition can occur from ductile to brittle fracture with maximum stresses between 85% and 95% of the tensile strength. Evidence of crack propagation features on fracture surfaces under scanning electron microscope (SEM) observation suggests crack initiation in void defects created by printing deposition that propagates longitudinally through line bonding interfaces along layers. Considering this, 3D-printed PEEK’s fatigue behaviour can be strongly related to printing conditions. Further research on the fatigue behaviour of 3D-printed PEEK is necessary to support its use in load-bearing implant applications.

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Section: Methodsmentioning

confidence: 99%

“…Fatigue tests were performed on the 3D-printed PEEK specimens under load-controlled conditions for three different stress levels. For each level, the maximum stress applied (

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

High-Cycle Fatigue Behaviour of Polyetheretherketone (PEEK) Produced by Additive Manufacturing

Rendas,

Imperadeiro,

Martins

et al. 2023

Polymers

Self Cite

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show abstract

“…In the case of thin-walled objects, it can be difficult to measure surface roughness, waviness, or form errors [19] using contact or optical measuring instruments. The results of bending tests of models produced by 3D printing in the FDM/FFF technology have been presented in several research papers [20][21][22], where the authors focused their attention on samples with a standard thickness of over 3 mm, usually with full filling. Moreover, papers [20,21] present the results of bending tests for materials based on composites and paper [22] for PEEK material.…”

Section: Introductionmentioning

confidence: 99%

“…The results of bending tests of models produced by 3D printing in the FDM/FFF technology have been presented in several research papers [20][21][22], where the authors focused their attention on samples with a standard thickness of over 3 mm, usually with full filling. Moreover, papers [20,21] present the results of bending tests for materials based on composites and paper [22] for PEEK material. These works, however, do not address the issue of generating G-codes because this problem arises, as shown in this article, only in the case of thin-walled models.…”

Section: Introductionmentioning

confidence: 99%

Flexural Properties of Thin-Walled Specimens with Square Hollow Sections 3D Printed from ABS Reinforced with Aramid Fibers

Bochnia,

Kozior,

Musialek

2023

Fibers

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This article studies the flexural behavior of thin-walled specimens with square hollow sections fabricated using fused deposition modeling (FDM). The specimens were 3D printed from an ABS filament reinforced with aramid fibers. Four wall thicknesses were analyzed. The strength data were collected during three-point flexural tests. There are visible, clear differences in the flexural properties between the X- or Y-oriented specimens and those printed in the Z direction, and they vary up to 70%. It was also found that the flexural strength was dependent on the G-codes controlling the print head’s motion, path, and position. For specimens with a thickness up to 1.4 mm, the infill pattern was linear, whereas 1.8 mm and 2 mm specimens needed a stitch, which had some negative effects on the strength properties.

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Additive manufacturing and mechanical performance of short fiber reinforced PEEK (polyether ether ketone) thermoplastic composites in a vacuum environment

Vatandaş,

Gümrük

2024

Int J Adv Manuf Technol

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Short fiber reinforced thermoplastic composites (SFRTC) have gained popularity in the material extrusion (MEX) method, which is an additive manufacturing (AM) technology, allowing for the simpler and more cost-effective production of polymer composites. However, parts produced using MEX 3D printing technology often exhibit poor mechanical properties and surface quality compared to products manufactured using injection molding, which is one of the main disadvantages of this method. Various methods are used to overcome these challenges, such as production in a vacuum environment, heat-based processes, ultrasonic vibrations, and others. The objective of this study was to achieve parts with lower porosity and improved mechanical properties when printed in a vacuum environment compared to an atmospheric environment. Additionally, an investigation into the optimization of printing parameters was conducted to determine the parameters that yield the highest mechanical properties. For this purpose, SFRTC parts were printed at different vacuum levels (0.5, 10, 100 mbar), and they were subjected to flexural tests to determine their mechanical properties. The results showed that the flexural stress and elastic modulus of the samples produced in a 0.5 mbar vacuum environment increased by 79.75% and 39.41%, respectively, compared to samples produced in an atmospheric environment. Furthermore, the cross-sectional images of the samples were examined using an optical microscope, revealing the lowest porosity in the samples printed in 0.5 mbar vacuum environment.

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Improvement of tensile and flexural properties of 3D printed PEEK through the increase of interfacial adhesion

Cited by 21 publications

References 38 publications

High-Cycle Fatigue Behaviour of Polyetheretherketone (PEEK) Produced by Additive Manufacturing

High-Cycle Fatigue Behaviour of Polyetheretherketone (PEEK) Produced by Additive Manufacturing

Flexural Properties of Thin-Walled Specimens with Square Hollow Sections 3D Printed from ABS Reinforced with Aramid Fibers

Additive manufacturing and mechanical performance of short fiber reinforced PEEK (polyether ether ketone) thermoplastic composites in a vacuum environment

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