Design, Development, and Characterization of 3D-Printed Poly-Ether-Ether-Ketone Polymer

Tyler Hawley, Aditya Pulipaka, Dr. Shaghayegh Bagheri, and Dr. Ali Beheshti, Volgenau School of Engineering, George Mason University, 4400 University Drive, Fairfax, VA, 22030

Biomedical devices have potential to benefit from increased customization and enhanced material quality, which can be implemented using additive manufacturing. Customization of these biomedical devices is necessary to fit the individual constraints of each patient, while material quality dictates longevity . This research aims to examine the additive manufacturing parameters of Poly-Ether-Ether-Ketone (PEEK), which is a thermoplastic with mechanical properties similar to osseous tissue. PEEK is a unique and promising material due to its biocompatibility and proficiency for use in additive manufacturing. The objective of this research is to determine the ideal set of fused deposition modeling parameters, using PEEK, which exhibits the optimal mechanical and surface qualities for use in biomedical applications aimed at tribo-corrosive environments.

A literature review was conducted to find the primary parameters to experiment with the fused deposition modeling of PEEK, which are: nozzle temperature, platform temperature, printing speed, layer height, and infill percentage.  In order to efficiently test the interactions of these parameters, a Taguchi experimental design was produced, being five parameters of three levels each, for a total of twenty-seven samples to experimentally produce. The influence of platform temperature on the samples’ crystallinity was a key deciding factor to orient the samples horizontally, where the sample’s largest surface area is in contact with the platform. Scratch tests and indentation tests will be repeatedly performed on the horizontally oriented samples. This process will be replicated with samples printed in a vertical orientation, where the smallest surface area is in contact with the platform. The results of the tests will be analyzed in order to determine the parameters to use for an optimal quality 3D printed part using PEEK. Overall, advances in additive manufacturing of composite Poly-Ether-Ether-Ketone maintain an encouraging outlook for the production of custom biomedical implants that possess properties similar to bone tissue.

Additional Abstract Information

Presenters: Tyler Hawley, Aditya Pulipaka

Institution: George Mason University

Type: Poster

Subject: Mechanical & Industrial Engineering

Status: Approved

Time and Location

Session: Poster 8
Date/Time: Tue 5:00pm-6:00pm
Session Number: 5620