8 Reasons to Use High-Performance Polymers in Additive Manufacturing

High-performance polymers (HPP) have been used in industry for several decades, particularly in injection molding and machining. However, in recent years, they have ceased to be materials exclusive to traditional engineering and have made their appearance in additive manufacturing. This type of polymer is characterized by properties superior to those of conventional polymers. We are talking here about greater strength, better wear resistance, and greater durability. Among the HPPs most commonly used in additive processes are the polyaryletherketone (PAEK) family, which includes PEEK and PEKK, and polyetherimide (PEI), better known by its trade name, ULTEM.

The processing of HPPs in 3D printing continues to be refined, but their role is increasingly important in solving real-world problems in increasingly complex value chains, with shorter lead times and optimized costs. Here, we explore eight reasons to choose high-performance polymers in additive manufacturing. The goal is to understand why these materials can move beyond being an experimental alternative to becoming an advanced manufacturing resource.

3D-printed parts in PEEK. (Photo Credit: Elecrow)

#1: Good Thermal Resistance

One of the most remarkable features of high-performance polymers is their thermal stability under extreme conditions. While standard plastics like ABS start to lose their mechanical properties at around 90–100 °C, materials such as PEEK maintain their structure during continuous use up to 250 °C and can withstand temperature spikes up to 300 °C. PEKK and PEI behave similarly, with heat deflection temperatures above 200 °C, making them a strong choice for applications where thermal stability is essential. This level of performance allows these polymers to be used in harsh industrial environments, including parts located near engines in automotive applications or structural supports in aerospace turbines.