How to 3D print high-performance materials (PAEK, PEI…): Experts give their advice!

The additive manufacturing sector has seen an expansion in high-performance materials research in recent years, particularly for polymers. These include high-performance thermoplastics, better known by their acronyms, PEEK, PEKK and PEI (ULTEM). We are also seeing the development of new materials such as PPSU or PVDF. These materials are sparking manufacturers’ interest as they offer greater mechanical properties. Some of these materials can even be reinforced with carbon fiber or glass, which gives them interesting properties. Even though the benefits of these materials are numerous, it should be noted that these materials are harder to print with, as they must meet demanding criteria. This is why we come to you today with another expert advice focusing on this family of materials. What are their characteristics? How do we use them in AM? And for which applications? We interviewed three industry experts to give you exclusive advice! Today we focus on 3D printing these materials using FDM technologies; in fact high performance materials can also be printed using SLS technologies. For your information, you can find a previous guide we wrote about these advanced thermoplastics polymers HERE.

Who are our experts?

Our first expert, Dr. Abraham Avalos, is the Head Scientist of AON3D’s 3D printing research department. AON3D is a Canadian manufacturer of high-performance 3D printers. He completed his PhD on polymer synthesis for biosensing applications, before working on fused deposition modeling of PEEK and CF PEEK to gain further expertise in this segment. Our second expert, Nicolas Morand is Kimya’s RDI & Industrialisation Manager at ARMOR: his mission is to design and produce their 3D printing materials, including a range of high-performance materials. Finally, our third expert is Bernd Rauch, Managing Partner of Rauch CNC Manufaktur, one of the leading 3D printing services for high-performance plastics in Europe, who has been involved in additive manufacturing since 2010. Bernd Rauch is responsible for the establishment and overall management of the AM (Additive Manufacturing) division. Our third expert not only has experience with FDM, but also with the SLS process and the “ThermoMelt” process, which is based on a patent from AIRBUS and which Rauch AM has in-house as a pilot user.

High-performance 3D printing materials: what are the benefits for the industry?

The PAEK family (PEEK, PEKK) and the PEI family have a number of advantages that could be grouped into three categories: good thermal properties, high mechanical characteristics and finally a set of various resistances (to solvents, acids, etc.).