How to 3D Print PEEK, PEKK, and ULTEM™

Summary

This webinar from AON 3D covers the essentials of 3D printing with high-performance thermoplastics like PEEK, PEKK, and ULTEM. Presented by Eric Beardsley and Viv Campbell, the session delves into the material properties, processing challenges, and hardware requirements necessary for successfully printing these advanced polymers. The speakers explain the different types of thermoplastics, their unique characteristics, and how to optimize printing conditions to reduce warping and enhance part quality. The webinar also introduces the AON M2 Plus printer, highlighting its capabilities in printing strong, industrial-grade parts with customizable parameters.

Takeaways

• 🔍 Aon3D's webinar focuses on high-performance 3D printing materials, including PEEK, PEKK, and ULTEM, with insights on material properties, processing, and hardware requirements.
• 👨‍💼 Eric Beardsley, with six years in additive manufacturing, leads the presentation, joined by Viv Campbell, a materials engineering expert.
• 🏢 Aon3D, founded by materials engineers, emphasizes material innovation and ROI-focused solutions for businesses, with clients from small companies to Fortune 500 corporations and government agencies.
• 🖨️ The Aon M2 Plus 3D printer, now in its fifth generation, is designed for industrial applications, capable of printing strong, large-scale parts with advanced polymers.
• 📊 The presentation categorizes thermoplastics into three types: commodity polymers (like PLA, ABS), engineering-grade polymers (like nylon), and high-performance polymers (such as PEEK and ULTEM).
• 🔬 Amorphous and semi-crystalline materials differ in molecular structure and performance: amorphous polymers are more dimensionally stable, while semi-crystalline ones offer higher strength and chemical resistance.
• 🔥 Printing high-temperature polymers requires chamber heating to control shrinkage and crystallization, which helps reduce warping, enhances interlayer adhesion, and improves part durability.
• 🔧 Hardware features for 3D printing high-performance materials include dual extrusion, customizable process parameters, open material systems, and temperature-controlled environments for optimized results.
• 💸 Closed 3D printing systems can limit material choices and increase costs, sometimes charging extra for licenses or upgrades, making open systems more cost-effective for long-term use.
• 🤝 Aon3D provides ongoing support and guidance for businesses using the M2 Plus, helping them quickly gain expertise in industrial additive manufacturing and improve productivity.

Q & A

What are the main materials discussed in the webinar for 3D printing?

The webinar discusses high-performance materials for 3D printing, focusing on PEEK, PEKK, and ULTEM. These materials are known for their strength, heat resistance, and suitability for demanding applications.

What is the significance of thermoplastics in additive manufacturing?

Thermoplastics are important in additive manufacturing due to their varying properties, such as flexibility, strength, and chemical resistance. They can be re-melted and re-shaped, making them ideal for 3D printing applications.

What is the difference between amorphous and semi-crystalline polymers?

Amorphous polymers have randomly ordered molecular structures and lack a sharp melting point, making them more dimensionally accurate and less likely to warp. Semi-crystalline polymers have ordered molecular chains, offering higher strength, but are more prone to shrinkage during cooling.

Why are high-performance polymers like PEEK and PEKK considered ideal for demanding applications?

High-performance polymers like PEEK and PEKK provide high strength-to-weight ratios, heat and chemical resistance, and are biocompatible. These properties make them suitable for industries such as aerospace, medical, and automotive.

What challenges can arise when printing with semi-crystalline materials?

Semi-crystalline materials tend to shrink as they crystallize, which can lead to warping and reduced interlayer weld strength. This is due to rapid thermal contraction during printing.

How does chamber heating help reduce residual stress during 3D printing?

Chamber heating allows parts to cool slowly and uniformly, reducing sharp thermal contractions that cause residual stress. This helps to minimize warping and improves interlayer adhesion in printed parts.

What factors should be considered when selecting a 3D printer for high-performance polymers?

Important factors include thermal conditions, chamber heating, the ability to change build sheet materials, and open materials systems. These features ensure better adhesion, uniform crystallization, and access to a wider range of materials.

Why is dual extrusion recommended in 3D printing complex geometries?

Dual extrusion allows the use of soluble supports and breakaway supports for complex designs, such as overhangs and internal geometries. It also reduces the need for manual post-processing, improving efficiency and print quality.

How do open materials systems benefit 3D printing?

Open materials systems provide access to a wide range of materials at competitive prices, allowing users to explore different polymers and optimize their 3D printing applications without restrictions imposed by proprietary systems.

What are the typical applications for high-performance polymers in 3D printing?

High-performance polymers are used in aerospace, medical, automotive, and regulated industries. Applications include metal replacements, medical tools and implants, bearings, gears, and components requiring heat and chemical resistance.