Preliminary Investigation of Poly-Ether-Ether-Ketone Based on Fused Deposition Modeling for Medical Applications

Abstract In this paper, poly(ether ether ketone) (PEEK) scaffold was manufactured using the fused deposition modeling (FDM) technology with a modified platform. The effect of processing parameters of FDM on the porosity and compressive strength of PEEK scaffold with uniform pores (0.8 mm of diameter) was optimized through Taguchi methodology. With the determined parameters, four kinds of PEEK scaffolds with gradient pores (0.4–0.8 mm, 0.6–1.0 mm, 0.8–1.2 mm, and 1.2–2.0 mm) were manufactured. The scaffolds were investigated using scanning electron microscopy. The results showed that the pores of scaffolds were interconnected with rough surface, which can allow the attachment, migration, and differentiation of cells for bone forming. The tensile strength, compressive max strength, and compressive yield strength of scaffolds were between 18 and 35 MPa, 197.83 and 370.42 MPa, and 26 and 36 MPa, respectively. The mechanical properties of the scaffolds can satisfy the loading requirements of human bones. Therefore, the PEEK scaffolds have a potential to be used in tissue engineering as implants.

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Effect of process parameters of fused deposition modeling on mechanical properties of poly-ether-ether-ketone and carbon fiber/poly-ether-ether-ketone

High Performance Polymers ◽

10.1177/09540083211067388 ◽

2022 ◽

pp. 095400832110673

Author(s):

Pei Wang ◽

Aigang Pan ◽

Liu Xia ◽

Yitao Cao ◽

Hongjie Zhang ◽

...

Keyword(s):

Mechanical Properties ◽

Process Parameters ◽

Fused Deposition Modeling ◽

Fused Deposition ◽

Ether Ether Ketone ◽

Poly Ether Ether Ketone ◽

Raster Angle ◽

Deposition Modeling ◽

Ether Ketone ◽

Nozzle Temperature

As a rapidly developing additive manufacturing technology, fused deposition modeling (FDM) has become widespread in many industry fields. It can fabricate complicated geometries using filament of thermoplastic materials such as PP, polylactic acid, acrylonitrile butadiene styrene, etc. However, poor mechanical properties of raw materials limit their application. Poly-ether-ether-ketone is a type of special engineering plastic with high performance, which could be further reinforced by adding carbon fibers (CFs). During FDM process, the mechanical properties of printed parts are largely subject to careful selection of process parameters. To improve the mechanical properties of PEEK and CF/PEEK 3D-printed parts, the effects of various process parameters including building orientation, raster angle, nozzle temperature, platform temperature, ambient temperature, printing speed, layer thickness, infill density, and number of printed parts on mechanical properties were investigated. The tensile fracture interfaces of printed parts were observed by scanning electron microscope (SEM) to explain the influence mechanism of process parameters. In the single factor experiments, flat and on-edge specimens show the best tensile and flexural strength, respectively; the specimens with raster angle ±45° and 0° show the best tensile and flexural strength, respectively. When the nozzle temperature at 500°C, platform temperature at 200°C, ambient temperature at 150°C, printing speed is 20 mm/s, layer thickness is 0.2 mm, and infill density is 100%, the printed parts exhibit the best mechanical properties.

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Mechanical Properties Optimization of Poly-Ether-Ether-Ketone via Fused Deposition Modeling

Materials ◽

10.3390/ma11020216 ◽

2018 ◽

Vol 11 (2) ◽

pp. 216 ◽

Cited By ~ 50

Author(s):

Xiaohu Deng ◽

Zhi Zeng ◽

Bei Peng ◽

Shuo Yan ◽

Wenchao Ke

Keyword(s):

Mechanical Properties ◽

Fused Deposition Modeling ◽

Fused Deposition ◽

Ether Ether Ketone ◽

Poly Ether Ether Ketone ◽

Deposition Modeling ◽

Ether Ketone

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Parameters Influencing the Outcome of Additive Manufacturing of Tiny Medical Devices Based on PEEK

Materials ◽

10.3390/ma13020466 ◽

2020 ◽

Vol 13 (2) ◽

pp. 466 ◽

Cited By ~ 5

Author(s):

Yiqiao Wang ◽

Wolf-Dieter Müller ◽

Adam Rumjahn ◽

Andreas Schwitalla

Keyword(s):

Medical Devices ◽

Fused Deposition Modeling ◽

High Accuracy ◽

Design Parameters ◽

Fused Deposition ◽

Polyether Ether Ketone ◽

Deposition Modeling ◽

3D Printed ◽

Ether Ketone

In this review, we discuss the parameters of fused deposition modeling (FDM) technology used in finished parts made from polyether ether ketone (PEEK) and also the possibility of printing small PEEK parts. The published articles reporting on 3D printed PEEK implants were obtained using PubMed and search engines such as Google Scholar including references cited therein. The results indicate that although many have been experiments conducted on PEEK 3D printing, the consensus on a suitable printing parameter combination has not been reached and optimized parameters for printing worth pursuing. The printing of reproducible tiny-sized PEEK parts with high accuracy has proved to be possible in our experiments. Understanding the relationships among material properties, design parameters, and the ultimate performance of finished objects will be the basis for further improvement of the quality of 3D printed medical devices based on PEEK and to expand the polymers applications.

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Observation of Shape and Dimensional Accuracy Changing of Parts in Time Intervals Manufactured by Additive Method Fused Deposition Modeling

Materials Science Forum ◽

10.4028/www.scientific.net/msf.919.182 ◽

2018 ◽

Vol 919 ◽

pp. 182-189

Author(s):

Ivan Molnár ◽

Róbert Hrušecký ◽

Ladislav Morovič ◽

Augustín Görög

Keyword(s):

Fused Deposition Modeling ◽

Coordinate Measuring Machine ◽

Dimensional Accuracy ◽

Medical Applications ◽

Cad Model ◽

Time Intervals ◽

Manufacturing Method ◽

Fused Deposition ◽

Deposition Modeling ◽

Measuring Machine

This article deals with the observation of shape and dimensional accuracy of parts after manufacturing in certain time intervals. The parts was manufactured by additive manufacturing method Fused Deposition Modeling (FDM). The shape and chosen dimension changes due to material shrinkage was observed on materials, namely Polylactic Acid (PLA) and Polyethylene Terephthalate Glycol (PET-G). These materials rank among health-conscious and usable in some medical applications. The parts were measured by using coordinate measuring machine (CMM) in certain time intervals and the shape and chosen dimensions was compared with the reference computer aided designed (CAD) model.

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Research on the Fused Deposition Modeling of Polyether Ether Ketone

Polymers ◽

10.3390/polym13142344 ◽

2021 ◽

Vol 13 (14) ◽

pp. 2344

Author(s):

Ruoxiang Gao ◽

Jun Xie ◽

Jinghui Yang ◽

Chaojie Zhuo ◽

Jianzhong Fu ◽

...

Keyword(s):

Tensile Strength ◽

Fused Deposition Modeling ◽

Fused Deposition ◽

Polyether Ether Ketone ◽

Raster Angle ◽

Deposition Modeling ◽

Ether Ketone ◽

Nozzle Temperature ◽

Warpage Deformation ◽

Printing Speed

As a special engineering polymer, polyether ether ketone (PEEK) has been used widely due to its excellent mechanical properties, high thermal stability, and chemical resistance. Fused deposition modeling (FDM) is a promising process for fabricating PEEK parts. However, due to the semi-crystalline property and high melting point of PEEK, determining appropriate process parameters is important to reduce warpage deformation and improve the mechanical properties of PEEK. In this article, the influence of raster angle and infill density was determined by single factor experiment, which are the two most important parameters. The results showed that samples with 0°/90° raster angle and 50% infill density had the best comprehensive properties in terms of warpage deformation, tensile strength, and specific strength. Subsequently, based on the results above, the effects of printing speed, nozzle temperature, platform temperature, raster width, and layer thickness were analyzed by orthogonal experiment. The results indicated that platform temperature had the greatest impact on warpage deformation while printing speed and nozzle temperature were significant parameters on tensile strength. Through optimization, warpage deformation of the samples could be reduced to almost 0 and tensile strength could increase by 19.6% (from 40.56 to 48.50 MPa). This will support the development of FDM for PEEK.

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Optimization of fused deposition modeling process parameters using the Taguchi method to improve the tensile properties of 3D-printed polyether ether ketone

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/14644207211017572 ◽

2021 ◽

pp. 146442072110175

Author(s):

Timoumi Mohamed ◽

Najoua Barhoumi ◽

Khalid Lamnawar ◽

Abderrahim Maazouz ◽

Amna Znaidi

Keyword(s):

Tensile Properties ◽

Young’S Modulus ◽

Layer Thickness ◽

Process Parameters ◽

Fused Deposition Modeling ◽

Young's Modulus ◽

Fused Deposition ◽

Polyether Ether Ketone ◽

Deposition Modeling ◽

Ether Ketone

The interesting mechanical properties of polyether ether ketone give the material a place among the foremost competitors when it comes to replacing metal. Fused deposition modeling has been recognized as an alternative method to process polyether ether ketone parts. In this study, the effect of different process parameters such as nozzle, bed, and radiant temperatures as well as printing speed and layer thickness on the tensile properties of three-dimensional printed polyether ether ketone was investigated. The optimization of the tensile properties of PEEK were studied by performing a reduced number of experiments, using the experimental design method based on the Taguchi approach which limits the number of experiments to 8 instead of 32. Results showed that a decent Young’s modulus was found by setting the nozzle temperature, print speed, and bed temperatures to their high levels and by setting the layer thickness and radiant temperature to their low level. Using these parameters, a Young’s modulus of 3.5 GPa was obtained, which represents 87.5% of the value indicated in the technical sheet. With these settings, we also found a tensile strength of 45.5 MPa, which corresponds to 46.4% of the value given by the studied polyether ether ketone material. A scanning electron microscopic investigation of the porosity and interlayer adhesion, confirmed that a higher bed temperature also tended to promote adhesion between layers.

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Optimization of the fused deposition modeling-based fabrication process for polylactic acid microneedles

Microsystems & Nanoengineering ◽

10.1038/s41378-021-00284-9 ◽

2021 ◽

Vol 7 (1) ◽

Author(s):

Libo Wu ◽

Jongho Park ◽

Yuto Kamaki ◽

Beomjoon Kim

Keyword(s):

Additive Manufacturing ◽

Polylactic Acid ◽

Chemical Etching ◽

Fused Deposition Modeling ◽

Sensory Nerve ◽

Nerve Fibers ◽

Fabrication Process ◽

Medical Applications ◽

Fused Deposition ◽

Deposition Modeling

AbstractA microneedle (MN) array is a novel biomedical device adopted in medical applications to pierce through the stratum corneum while targeting the viable epidermis and dermis layers of the skin. Owing to their micron-scale dimensions, MNs can minimize stimulations of the sensory nerve fibers in the dermis layer. For medical applications, such as wound healing, biosensing, and drug delivery, the structure of MNs significantly influences their mechanical properties. Among the various microfabrication methods for MNs, fused deposition modeling (FDM), a commercial 3D printing method, shows potential in terms of the biocompatibility of the printed material (polylactic acid (PLA)) and preprogrammable arbitrary shapes. Owing to the current limitations of FDM printer resolution, conventional micron-scale MN structures cannot be fabricated without a post-fabrication process. Hydrolysis in an alkaline solution is a feasible approach for reducing the size of PLA needles printed via FDM. Moreover, weak bonding between PLA layers during additive manufacturing triggers the detachment of PLA needles before etching to the expected sizes. Furthermore, various parameters for the fabrication of PLA MNs with FDM have yet to be sufficiently optimized. In this study, the thermal parameters of the FDM printing process, including the nozzle and printing stage temperatures, were investigated to bolster the interfacial bonding between PLA layers. Reinforced bonding was demonstrated to address the detachment challenges faced by PLA MNs during the chemical etching process. Furthermore, chemical etching parameters, including the etchant concentration, environmental temperature, and stirring speed of the etchant, were studied to determine the optimal etching ratio. To develop a universal methodology for the batch fabrication of biodegradable MNs, this study is expected to optimize the conditions of the FDM-based fabrication process. Additive manufacturing was employed to produce MNs with preprogrammed structures. Inclined MNs were successfully fabricated by FDM printing with chemical etching. This geometrical structure can be adopted to enhance adhesion to the skin layer. Our study provides a useful method for fabricating MN structures for various biomedical applications.

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