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Polymers
Volume 15
Issue 18
10.3390/polym15183825
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Article

Design and Modification of a Material Extrusion 3D Printer to Manufacture Functional Gradient PEEK Components

by
Tobias Ritter
1,2,
Eric McNiffe
1,2,
Tom Higgins
1,2,
Omid Sam-Daliri
1,2,
Tomas Flanagan
3,
Michael Walls
4,
Pouyan Ghabezi
1,2,5,*,
William Finnegan
1,2,5,
Sinéad Mitchell
1,6 and
Noel M. Harrison
1,2,5,6
1
School of Engineering, University of Galway, Galway, Ireland
2
I-Form, the SFI Research Centre for Advanced Manufacturing, Ireland
3
Éire Composites Teo, Údarás Industrial Estate, An Choill Rua, Inverin, Co., H91 Y923 Galway, Ireland
4
CTL Tástáil Teo, Údarás Industrial Estate, An Choill Rua, Inverin, Co., H91 Y923 Galway, Ireland
5
Construct Innovate & SFI MaREI Research Centre, University of Galway, Galway, Ireland
6
Ryan Institute for Environmental, Marine and Energy Research, University of Galway, Galway, Ireland
*
Author to whom correspondence should be addressed.
Polymers 2023, 15(18), 3825; https://doi.org/10.3390/polym15183825
Submission received: 12 July 2023 / Revised: 23 August 2023 / Accepted: 27 August 2023 / Published: 19 September 2023
(This article belongs to the Special Issue Advances in Rheology and Polymer Processing)
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Abstract

In recent years, the creative use of polymers has been expanded as the range of achievable material properties and options for manufacturing and post-processing continually grows. The main goal of this research was to design and develop a fully-functioning material extrusion additive manufacturing device with the capability to produce functionally graded high-temperature thermoplastic PEEK (polyether ether ketone) materials through the manipulation of microstructure during manufacturing. Five different strategies to control the chamber temperature and crystallinity were investigated, and concepts of thermal control were introduced to govern the crystallisation and cooling mechanics during the extrusion process. The interaction of individually deposited beads of material during the printing process was investigated using scanning electron microscopy to observe and quantify the porosity levels and interlayer bonding strength, which affect the quality of the final part. Functional testing of the printed parts was carried out to identify crystallinity, boundary layer adhesion, and mechanical behaviour. Furnace cooling and annealing were found to be the most effective methods, resulting in the highest crystallinity of the part. Finally, a functionally graded material cylindrical part was printed successfully, incorporating both low and high crystalline regions.
Keywords: material extrusion printing; functionally graded materials; PEEK; fused deposition modelling; additive manufacturing material extrusion printing; functionally graded materials; PEEK; fused deposition modelling; additive manufacturing

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MDPI and ACS Style

Ritter, T.; McNiffe, E.; Higgins, T.; Sam-Daliri, O.; Flanagan, T.; Walls, M.; Ghabezi, P.; Finnegan, W.; Mitchell, S.; Harrison, N.M. Design and Modification of a Material Extrusion 3D Printer to Manufacture Functional Gradient PEEK Components. Polymers 2023, 15, 3825. https://doi.org/10.3390/polym15183825

AMA Style

Ritter T, McNiffe E, Higgins T, Sam-Daliri O, Flanagan T, Walls M, Ghabezi P, Finnegan W, Mitchell S, Harrison NM. Design and Modification of a Material Extrusion 3D Printer to Manufacture Functional Gradient PEEK Components. Polymers. 2023; 15(18):3825. https://doi.org/10.3390/polym15183825

Chicago/Turabian Style

Ritter, Tobias, Eric McNiffe, Tom Higgins, Omid Sam-Daliri, Tomas Flanagan, Michael Walls, Pouyan Ghabezi, William Finnegan, Sinéad Mitchell, and Noel M. Harrison. 2023. "Design and Modification of a Material Extrusion 3D Printer to Manufacture Functional Gradient PEEK Components" Polymers 15, no. 18: 3825. https://doi.org/10.3390/polym15183825

APA Style

Ritter, T., McNiffe, E., Higgins, T., Sam-Daliri, O., Flanagan, T., Walls, M., Ghabezi, P., Finnegan, W., Mitchell, S., & Harrison, N. M. (2023). Design and Modification of a Material Extrusion 3D Printer to Manufacture Functional Gradient PEEK Components. Polymers, 15(18), 3825. https://doi.org/10.3390/polym15183825

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