Effect of the feeding process on variable component printing of carbon fiber/polyether-ether-ketone composites
While fused filament fabrication (FFF) remains the predominant technique for polyetheretherketone (PEEK) composite printing, its inherent limitations in achieving interfacial-gradient composition control constrain the capability for variable component printing. Although 3D printing based on screw ex...
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2025.2509612 |
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| author | Beining Zhang Siwei Lu Yang Li Yunze Wang Dichen Li |
| author_facet | Beining Zhang Siwei Lu Yang Li Yunze Wang Dichen Li |
| author_sort | Beining Zhang |
| collection | DOAJ |
| description | While fused filament fabrication (FFF) remains the predominant technique for polyetheretherketone (PEEK) composite printing, its inherent limitations in achieving interfacial-gradient composition control constrain the capability for variable component printing. Although 3D printing based on screw extrusion has recently emerged as a promising alternative for variable component composites, the key processes involved have not been systematically studied. This study employs a custom-designed screw extrusion system (16 mm diameter) with dual-material feeding capability (PEEK and 40 wt% carbon fiber/PEEK) to systematically investigate feedstock delivery mechanisms governing compositional gradient formation. Experimental results demonstrate three key findings: (1) Continuous carbon fiber (CF) content regulation (0–40 wt%) is achievable through the control of bilateral feeding ratios; (2) Complete melt chamber replacement occurs at a 2560 mm CF/PEEK feeding stroke, corresponding to the maximum fiber concentration; (3) Gradual feeding ratio modulation reduces the required transition distances by 50% compared to abrupt material switching. The optimised process successfully fabricates geometrically complex gradient components, significantly expanding the multifunctional engineering potential of PEEK composites. |
| format | Article |
| id | doaj-art-9dcde2a25aab49eab2cf6251ab79f4df |
| institution | Kabale University |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-9dcde2a25aab49eab2cf6251ab79f4df2025-08-20T03:25:59ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2025.2509612Effect of the feeding process on variable component printing of carbon fiber/polyether-ether-ketone compositesBeining Zhang0Siwei Lu1Yang Li2Yunze Wang3Dichen Li4State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an, Shaanxi, People's Republic of ChinaState Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an, Shaanxi, People's Republic of ChinaState Industry-Education Integration Centre for Medical Technology, Xi'an Jiaotong University, Xi'an, Shaanxi, People's Republic of ChinaNational Medical Products Administration (NMPA) Key Laboratory for Research and Evaluation of Additive Manufacturing Medical Devices, Xi'an, Shaanxi, People's Republic of ChinaState Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an, Shaanxi, People's Republic of ChinaWhile fused filament fabrication (FFF) remains the predominant technique for polyetheretherketone (PEEK) composite printing, its inherent limitations in achieving interfacial-gradient composition control constrain the capability for variable component printing. Although 3D printing based on screw extrusion has recently emerged as a promising alternative for variable component composites, the key processes involved have not been systematically studied. This study employs a custom-designed screw extrusion system (16 mm diameter) with dual-material feeding capability (PEEK and 40 wt% carbon fiber/PEEK) to systematically investigate feedstock delivery mechanisms governing compositional gradient formation. Experimental results demonstrate three key findings: (1) Continuous carbon fiber (CF) content regulation (0–40 wt%) is achievable through the control of bilateral feeding ratios; (2) Complete melt chamber replacement occurs at a 2560 mm CF/PEEK feeding stroke, corresponding to the maximum fiber concentration; (3) Gradual feeding ratio modulation reduces the required transition distances by 50% compared to abrupt material switching. The optimised process successfully fabricates geometrically complex gradient components, significantly expanding the multifunctional engineering potential of PEEK composites.https://www.tandfonline.com/doi/10.1080/17452759.2025.2509612CF/PEEKvariable component compositesscrew extrusion printing |
| spellingShingle | Beining Zhang Siwei Lu Yang Li Yunze Wang Dichen Li Effect of the feeding process on variable component printing of carbon fiber/polyether-ether-ketone composites Virtual and Physical Prototyping CF/PEEK variable component composites screw extrusion printing |
| title | Effect of the feeding process on variable component printing of carbon fiber/polyether-ether-ketone composites |
| title_full | Effect of the feeding process on variable component printing of carbon fiber/polyether-ether-ketone composites |
| title_fullStr | Effect of the feeding process on variable component printing of carbon fiber/polyether-ether-ketone composites |
| title_full_unstemmed | Effect of the feeding process on variable component printing of carbon fiber/polyether-ether-ketone composites |
| title_short | Effect of the feeding process on variable component printing of carbon fiber/polyether-ether-ketone composites |
| title_sort | effect of the feeding process on variable component printing of carbon fiber polyether ether ketone composites |
| topic | CF/PEEK variable component composites screw extrusion printing |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2025.2509612 |
| work_keys_str_mv | AT beiningzhang effectofthefeedingprocessonvariablecomponentprintingofcarbonfiberpolyetheretherketonecomposites AT siweilu effectofthefeedingprocessonvariablecomponentprintingofcarbonfiberpolyetheretherketonecomposites AT yangli effectofthefeedingprocessonvariablecomponentprintingofcarbonfiberpolyetheretherketonecomposites AT yunzewang effectofthefeedingprocessonvariablecomponentprintingofcarbonfiberpolyetheretherketonecomposites AT dichenli effectofthefeedingprocessonvariablecomponentprintingofcarbonfiberpolyetheretherketonecomposites |