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Advancements in Fused Deposition Modeling 3D Printing of Polymers: Material Properties and Thermal Behavior

A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Processing and Engineering".

Deadline for manuscript submissions: 31 July 2026 | Viewed by 9192

Special Issue Editors

Dr. Babak Eslami

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Widener University, Chester, PA 19013, USA
Interests: 3D printing; atomic force microscopy; material characterization; nanotechnology
Special Issues, Collections and Topics in MDPI journals
Dr. Saeed Tiari

E-Mail Website
Guest Editor
Biomedical Engineering Department, Widener University, One University Pl, Chester, PA 19013, USA
Interests: thermal energy storage; CFD; biotransport phenomena
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Fused Deposition Modeling (FDM) has become one of the most widely adopted additive manufacturing techniques due to its accessibility, material versatility, and growing industrial relevance. As the demand for high-performance polymer-based components increases, understanding the intricate relationship between material properties, process parameters, and thermal behavior will become critical for advancing FDM applications. This Special Issue aims to compile cutting-edge research on the development, characterization, and optimization of polymer materials used in FDM 3D printing.

We invite the submission of original research articles and reviews that explore polymer behavior during and after the printing process, including thermal transitions, crystallization, thermal conductivity, and heat-induced degradation. Topics of interest include but are not limited to material formulation and modification, the modeling of thermal behavior, process–structure–property relationships, multi-material and functional printing, and post-processing techniques used to enhance mechanical or thermal performance.

This Special Issue will serve as a platform for researchers, engineers, and industry professionals to share insights that will drive the next generation of polymer FDM applications. Contributions that combine experimental work with simulation or offer multidisciplinary perspectives are especially encouraged.

Dr. Babak Eslami
Dr. Saeed Tiari
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Polymers is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • fused deposition modeling (FDM)
  • 3D printing of polymers
  • thermal behavior
  • material characterization
  • process–structure–property relationships
  • polymer composites
  • additive manufacturing

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Published Papers (3 papers)

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Research

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15 pages, 4426 KB  
Article
Novel Low-Crystallinity Polyetheretherketone Copolymers for 3D Printing
by Azamat Zhansitov, Zhanna Kurdanova, Kamila Shakhmurzova, Azamat Slonov, Azamat Khashirov, Elena Rzhevskaya, Khasan Musov, Alanbek Tlupov and Svetlana Khashirova
Polymers 2026, 18(5), 558; https://doi.org/10.3390/polym18050558 - 25 Feb 2026
Viewed by 312
Abstract
To improve the quality of additive manufacturing of PEEK parts, copolymers with varying 4,4′-dichlorodiphenylsulfone (DCDPS) contents were synthesized. A study of the thermophysical properties of the resulting copolymers revealed that increasing the DCDPS content leads to lower melting temperatures, crystallization temperatures, and degree [...] Read more.
To improve the quality of additive manufacturing of PEEK parts, copolymers with varying 4,4′-dichlorodiphenylsulfone (DCDPS) contents were synthesized. A study of the thermophysical properties of the resulting copolymers revealed that increasing the DCDPS content leads to lower melting temperatures, crystallization temperatures, and degree of crystallinity, while simultaneously increasing the glass transition temperature. It was found that structural amorphization leads to a predictable decrease in the strength and elastic modulus of both cast and printed samples. However, at a DCDPS concentration of 15%, the decrease in mechanical properties is offset by an increase in polymer chain rigidity. The practical result of this study was the successful adaptation of the material to FDM printing: copolymers with DCDPS contents in the range of 5–20% ensured stable molding without deformation or delamination, demonstrating an optimal balance between processability and performance. Full article
(This article belongs to the Special Issue Advancements in Fused Deposition Modeling 3D Printing of Polymers: Material Properties and Thermal Behavior)
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25 pages, 19691 KB  
Article
Effects of Post-Heat Treatment on Mechanical and Tribological Properties of 3D-Printed PLA and PEEK Structures
by Yunxiang Deng and Li Chang
Polymers 2026, 18(2), 253; https://doi.org/10.3390/polym18020253 - 16 Jan 2026
Viewed by 467
Abstract
In the present study, post-heat treatment was applied to improve the mechanical and tribological performance of 3D-printed polymer components. Two polymers, i.e., polylactic acid (PLA) and polyether ether ketone (PEEK), were used as base materials. Re-entrant structures were incorporated into printed specimens to [...] Read more.
In the present study, post-heat treatment was applied to improve the mechanical and tribological performance of 3D-printed polymer components. Two polymers, i.e., polylactic acid (PLA) and polyether ether ketone (PEEK), were used as base materials. Re-entrant structures were incorporated into printed specimens to mitigate friction-induced vibrations (FIV). The results showed that the heat-treatment process effectively enhanced the mechanical properties of both materials by increasing their elastic modulus and yield strength. Specifically, the tensile and compressive strengths of heat-treated PLA increased from 44.14 MPa to 47.66 MPa and from 68 MPa to 82 MPa, respectively. A similar trend was observed for heat-treated PEEK, with tensile strength increasing from 75.53 MPa to 84.91 MPa and compressive strength from 106 MPa to 123 MPa. Furthermore, the increased stiffness enabled the re-entrant structures to more effectively reduce FIV during the sliding process of specimens. However, heat treatment produced contrasting effects on the wear performance of the two polymers. The specific wear rate of the heat-treated PLA sample with the re-entrant structure increased from 2.36 × 10−5 mm3/(N · m) to 4.5 × 10−4 mm3/(N · m), while it decreased for the PEEK sample from 3.18 × 10−6 mm3/(N · m) to 6.2 × 10−7 mm3/(N · m). Microscopic observations revealed that this difference was due to the variations in the brittleness of the treated materials, which influenced wear-debris formation and the development of the transfer film on the steel counterface. These findings demonstrate that post-heat treatment is an effective method for tailoring and optimizing the mechanical behavior of printed polymers while also emphasizing the necessity of systematically evaluating its influence on the tribological performance of printed engineering parts subjected to different sliding conditions. Full article
(This article belongs to the Special Issue Advancements in Fused Deposition Modeling 3D Printing of Polymers: Material Properties and Thermal Behavior)
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Review

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26 pages, 2731 KB  
Review
Recent Advances in PEEK for Biomedical Applications: A Comprehensive Review of Material Properties, Processing, and Additive Manufacturing
by Samreen Dallal, Babak Eslami and Saeed Tiari
Polymers 2025, 17(14), 1968; https://doi.org/10.3390/polym17141968 - 17 Jul 2025
Cited by 18 | Viewed by 7827
Abstract
Polyetheretherketone (PEEK) is a high-performance thermoplastic polymer widely recognized for its distinct mechanical strength, chemical resistance, and biocompatibility. These characteristics make it suitable for a wide range of applications, particularly in medical, aerospace, chemical, and electronics fields. Conventional processing techniques, such as 3D [...] Read more.
Polyetheretherketone (PEEK) is a high-performance thermoplastic polymer widely recognized for its distinct mechanical strength, chemical resistance, and biocompatibility. These characteristics make it suitable for a wide range of applications, particularly in medical, aerospace, chemical, and electronics fields. Conventional processing techniques, such as 3D printing, molding, and extrusion, are widely employed for PEEK fabrication. This review critically examines recent advancements in PEEK research, with an emphasis on additive manufacturing techniques that are expanding its applications in the medical field. We provide an in-depth analysis of PEEK’s intrinsic properties, diverse processing methods, and current challenges that hinder its wider adoption. In addition to evaluating PEEK’s performance, this review compares it with alternative biomaterials—such as titanium and ultra-high molecular weight polyethylene (UHMWPE)—to explore its advantages and limitations in biomedical applications. Furthermore, this review discusses cost considerations, regulatory constraints, long-term clinical performance challenges, and failure modes that are essential for validating and ensuring the reliability of PEEK in clinical use. By synthesizing the recent literature, particularly from the last decade, this review highlights the significant potential of PEEK and underscores ongoing research efforts aimed at overcoming its limitations, paving the way for its broader implementation in advanced technological applications. Full article
(This article belongs to the Special Issue Advancements in Fused Deposition Modeling 3D Printing of Polymers: Material Properties and Thermal Behavior)
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