Printability assessment and mechanical properties of filament-free 3D printed polyether-ether-ketone (PEEK) composites
The study focuses on the novel development and printability of hydroxyapatite/magnesium-orthosilicate (HAp/Mg2SiO4) reinforced PEEK composites using filament-free 3D printing (3DP) and an evaluation of its mechanical properties toward advancing customizable orthopedic implant manufacturing technolog...
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| Main Authors: | , , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-09-01
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| Series: | Journal of Materials Research and Technology |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425019490 |
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| Summary: | The study focuses on the novel development and printability of hydroxyapatite/magnesium-orthosilicate (HAp/Mg2SiO4) reinforced PEEK composites using filament-free 3D printing (3DP) and an evaluation of its mechanical properties toward advancing customizable orthopedic implant manufacturing technology. Thermal and melt properties of PEEK composite pellets with varying proportions of HAp/Mg2SiO4 (PA-20/5 and PB-25/5 wt%) were evaluated to assess their printability. Degree of crystallinity and coefficient of linear thermal expansion properties decreased with an increase in filler inclusion leading to enhanced dimensional stability of composites. Environment and build-plate temperatures were optimized based on the obtained thermal properties to minimize print-induced defects like solidification-induced shrinkage and warpage. Complex viscosity, storage and loss modulus of the developed composites increased with filler inclusion. Lower complex viscosity at higher frequency and shear thinning behaviors were observed in the composites as compared to pure PEEK. The meticulous assessment on printability enabled the successful printing of developed composites with enhanced material flow, interfacial adhesion, and dimensional stability. 3DP parts were then subject to mechanical testing showcasing the increase in modulus of composites with filler inclusion. PB exhibited 56.06 %, 26.11 % and 17.28 % higher tensile, flexural, and compressive modulus when compared with pure PEEK (P0). Meanwhile, the ultimate strength of the composites was lower than that of pure PEEK with PB showing 57.83 %, 43.83 % and 1.54 % lower tensile, flexural, and compressive strength. The decrease in mechanical strength of composites is attributed to higher concentrations of the fillers (>20 wt%). 3DP of developed novel composites demonstrates potential for developing customizable orthopedic implants. |
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| ISSN: | 2238-7854 |