Development of fused deposition modelling and printing patterns for PEEK

Fused filament fabrication, also known as 3D printing, is a unique kind of manufacturing technology. This process is highly automated and relatively economical for small scale production. Its high level of precision and accuracy allow users to quickly customise and fabricate 3D structures without the use of expensive machinery [1]. 3D printing allows for rapid-prototyping without the use of expensive equipment. However, its application in many industries is still very limited as most research revolves around weaker material like PLA (Polylactic Acid) and ABS (Acrylonitrile Butadiene Styrene). There is, therefore, a need to investigate this stronger engineering material, PEEK (Polyether Ether Ketone). In 3D printing, the successive layering process often produce defects which compromise on the strength and durability of the final product [1]. Past studies have accurately identified printing pattern and infill density as the two most important factors which will directly influence the mechanical properties of PLA and ABS [2]. Nonetheless, there have been no specific studies of these factors on PEEK. The objective of this paper was to evaluate the effect of printing pattern, number of shells and density on the mechanical properties of PEEK. Corresponding experiments were conducted to measure the mechanical strength and elastic modulus. In addition, a 3D printer capable of printing PEEK was designed. The modification and design process were also documented in this paper.Bachelor of Engineering (Aerospace Engineering