article · Journal of Applied Polymer Science
Poly(ether ketone ketone), or PEKK, is a high-performance thermoplastic considered an attractive alternative to poly(ether ether ketone) due to its mechanical strength, thermal stability, and chemical resistance. Research on fused deposition modelling investigated how nozzle temperature, layer thickness, and layer orientation influence the structural and physical properties of 3D-printed PEKK components. Tensile testing, electron microscopy, and thermal analyses revealed that the optimum printing settings are a layer thickness of 0.15 millimetres, a nozzle temperature of 380 degrees Celsius, and a 45-degree alternating layer orientation. Furthermore, post-printing thermal annealing was applied to relieve residual stresses and raise material crystallinity. Heating printed samples at 240 degrees Celsius for one hour increased crystallinity by 24 per cent, which enhanced the elastic modulus by approximately 14 per cent, tensile strength by 17 per cent, and the glass transition temperature by 17.2 degrees Celsius.
High-performance polymers are essential for demanding engineering environments where standard plastics fail. Demonstrating that PEKK can be reliably processed using standard additive manufacturing, and subsequently reinforced through simple heat treatments, provides engineers and fabricators with a clearer route to producing strong, chemically resistant parts with complex geometries without expensive tooling.
The findings are relevant to high-performance component manufacturers seeking alternatives to PEEK using additive manufacturing. By defining exact processing parameters and a successful thermal annealing regime, this work sits at an applied and tested stage, providing practical baseline data for industrial 3D printing users looking to achieve specific mechanical and thermal targets.
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Abstract Poly(ether ketone ketone) (PEKK) is a thermoplastic of the poly(aryl ether ketone) (PAEK) family, with excellent mechanical and thermal performances and high chemical resistance properties. This makes it an appealing material in high‐performance applications as a replacement for poly (ether ether ketone) (PEEK). PEKK was thus selected in this study as a base material for application in 3D printing. The effects of nozzle temperature, layer orientation and layer thickness on the final properties of 3D‐printed PEKK parts were investigated. Furthermore, we assessed the mechanical and morphological features of printed samples through tensile tests and scanning electron microscope, respectively. Thermal properties of samples were also evaluated through DSC and DMA analysis. Optimum printing parameters were found at 0.15 mm layer thickness, 380°C nozzle temperature, and [45/−45°] layer orientation. The printed PEKK samples were annealed at various temperatures to allow the relaxation of residual stress and enhance the degree of crystallinity. Samples annealed for 1 h at 240°C have shown an improved elastic modulus by ~14%, tensile strength by 17%, and glass transition temperature by 17.2°C from the increased by 24% degree of crystallinity.
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DOI: 10.1002/app.54078
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