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Rodzeń K, O’Donnell E, Hasson F, McIlhagger A, Meenan BJ, Ullah J, Strachota B, Strachota A, Duffy S, Boyd A. Advanced 3D Printing of Polyetherketoneketone Hydroxyapatite Composites via Fused Filament Fabrication with Increased Interlayer Connection. MATERIALS (BASEL, SWITZERLAND) 2024; 17:3161. [PMID: 38998244 PMCID: PMC11242051 DOI: 10.3390/ma17133161] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/24/2024] [Revised: 06/12/2024] [Accepted: 06/13/2024] [Indexed: 07/14/2024]
Abstract
Additively manufactured implants, surgical guides, and medical devices that would have direct contact with the human body require predictable behaviour when stress is applied during their standard operation. Products built with Fused Filament Fabrication (FFF) possess orthotropic characteristics, thus, it is necessary to determine the properties that can be achieved in the XY- and Z-directions of printing. A concentration of 10 wt% of hydroxyapatite (HA) in polyetherketoneketone (PEKK) matrix was selected as the most promising biomaterial supporting cell attachment for medical applications and was characterized with an Ultimate Tensile Strength (UTS) of 78.3 MPa and 43.9 MPa in the XY- and Z-directions of 3D printing, respectively. The effect of the filler on the crystallization kinetics, which is a key parameter for the selection of semicrystalline materials suitable for 3D printing, was explained. This work clearly shows that only in situ crystallization provides the ability to build parts with a more thermodynamically stable primary form of crystallites.
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Affiliation(s)
- Krzysztof Rodzeń
- School of Engineering, Ulster University, York St, Belfast BT15 1ED, UK; (E.O.); (F.H.); (A.M.); (B.J.M.); (J.U.); (S.D.)
| | - Eiméar O’Donnell
- School of Engineering, Ulster University, York St, Belfast BT15 1ED, UK; (E.O.); (F.H.); (A.M.); (B.J.M.); (J.U.); (S.D.)
| | - Frances Hasson
- School of Engineering, Ulster University, York St, Belfast BT15 1ED, UK; (E.O.); (F.H.); (A.M.); (B.J.M.); (J.U.); (S.D.)
| | - Alistair McIlhagger
- School of Engineering, Ulster University, York St, Belfast BT15 1ED, UK; (E.O.); (F.H.); (A.M.); (B.J.M.); (J.U.); (S.D.)
| | - Brian J. Meenan
- School of Engineering, Ulster University, York St, Belfast BT15 1ED, UK; (E.O.); (F.H.); (A.M.); (B.J.M.); (J.U.); (S.D.)
| | - Jawad Ullah
- School of Engineering, Ulster University, York St, Belfast BT15 1ED, UK; (E.O.); (F.H.); (A.M.); (B.J.M.); (J.U.); (S.D.)
| | - Beata Strachota
- Institute of Macromolecular Chemistry v.v.i., Academy of Sciences of the Czech Republic, Heyrovskeho nam. 2, 162 00 Praha, Czech Republic; (B.S.); (A.S.)
| | - Adam Strachota
- Institute of Macromolecular Chemistry v.v.i., Academy of Sciences of the Czech Republic, Heyrovskeho nam. 2, 162 00 Praha, Czech Republic; (B.S.); (A.S.)
| | - Sean Duffy
- School of Engineering, Ulster University, York St, Belfast BT15 1ED, UK; (E.O.); (F.H.); (A.M.); (B.J.M.); (J.U.); (S.D.)
| | - Adrian Boyd
- School of Engineering, Ulster University, York St, Belfast BT15 1ED, UK; (E.O.); (F.H.); (A.M.); (B.J.M.); (J.U.); (S.D.)
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Acierno D, Patti A. Fused Deposition Modelling (FDM) of Thermoplastic-Based Filaments: Process and Rheological Properties-An Overview. MATERIALS (BASEL, SWITZERLAND) 2023; 16:7664. [PMID: 38138805 PMCID: PMC10744784 DOI: 10.3390/ma16247664] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/14/2023] [Revised: 12/08/2023] [Accepted: 12/11/2023] [Indexed: 12/24/2023]
Abstract
The fused deposition modeling (FDM) process, an extrusion-based 3D printing technology, enables the manufacture of complex geometrical elements. This technology employs diverse materials, including thermoplastic polymers and composites as well as recycled resins to encourage sustainable growth. FDM is used in a variety of industrial fields, including automotive, biomedical, and textiles, as a rapid prototyping method to reduce costs and shorten production time, or to develop items with detailed designs and high precision. The main phases of this technology include the feeding of solid filament into a molten chamber, capillary flow of a non-Newtonian fluid through a nozzle, layer deposition on the support base, and layer-to-layer adhesion. The viscoelastic properties of processed materials are essential in each of the FDM steps: (i) predicting the printability of the melted material during FDM extrusion and ensuring a continuous flow across the nozzle; (ii) controlling the deposition process of the molten filament on the print bed and avoiding fast material leakage and loss of precision in the molded part; and (iii) ensuring layer adhesion in the subsequent consolidation phase. Regarding this framework, this work aimed to collect knowledge on FDM extrusion and on different types of rheological properties in order to forecast the performance of thermoplastics.
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Affiliation(s)
- Domenico Acierno
- Regional Center of Competence New Technologies for Productive Activities Scarl, Via Nuova Agnano 11, 80125 Naples, Italy;
| | - Antonella Patti
- Department of Civil Engineering and Architecture (DICAr), University of Catania, Viale Andrea Doria 6, 95125 Catania, Italy
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Carrola M, Fallahi H, Koerner H, Pérez LM, Asadi A. Fundamentals of Crystalline Evolution and Properties of Carbon Nanotube-Reinforced Polyether Ether Ketone Nanocomposites in Fused Filament Fabrication. ACS APPLIED MATERIALS & INTERFACES 2023; 15:22506-22523. [PMID: 37099604 PMCID: PMC10853907 DOI: 10.1021/acsami.3c01307] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/29/2023] [Accepted: 04/12/2023] [Indexed: 05/11/2023]
Abstract
As fused filament fabrication (FFF) continues to gain popularity, many studies are turning to nanomaterials or optimization of printing parameters to improve the materials' properties; however, many overlook how materials formulation and additive manufacturing (AM) processes cooperatively engineer the evolution of properties across length scales. Evaluating the in-process evolution of the nanocomposite using AM will provide a fundamental understanding of the material's microstructure, which can be tailored to create unique characteristics in functionality and performance. In this study, the crystallinity behavior of polyetheretherketone (PEEK) was studied in the presence of carbon nanotubes (CNTs) as a nucleation aid for improved crystallization during FFF processing. Using various characterization techniques and molecular dynamics simulations, it was discovered that the crystallization behavior of extruded filaments is very different from that of 3D printed roads. Additionally, the printed material exhibited cold crystallization, and the CNT addition increased the crystallization of printed roads, which were amorphous without CNT addition. Tensile strength and modulus were increased by as much as 42 and 51%, respectively, due to higher crystallinity during printing. Detailed knowledge on the morphology of PEEK-CNT used in FFF allows gaining a fundamental understanding of the morphological evolution occurring during the AM process that in turn enables formulating materials for the AM process to achieve tailored mechanical and functional properties, such as crystallinity or conductivity.
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Affiliation(s)
- Mia Carrola
- Department
of Materials Science & Engineering, Texas A&M University, College Station, Texas 77843, United States
| | - Hamed Fallahi
- Department
of Mechanical Engineering, Texas A&M
University, College Station, Texas 77843, United States
| | - Hilmar Koerner
- Materials
& Manufacturing Directorate, Air Force
Research Laboratory, WPAFB, Dayton, Ohio 45430, United States
| | - Lisa M. Pérez
- High
Performance Research Computing, Texas A&M
University, MS 3361, College Station, Texas 77843-3361, United States
| | - Amir Asadi
- Department
of Materials Science & Engineering, Texas A&M University, College Station, Texas 77843, United States
- Department
of Mechanical Engineering, Texas A&M
University, College Station, Texas 77843, United States
- Department
of Engineering Technology & Industrial Distribution, Texas A&M University, College Station, Texas 77843, United States
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Extrusion-Based Technology in Additive Manufacturing: A Comprehensive Review. ARABIAN JOURNAL FOR SCIENCE AND ENGINEERING 2022. [DOI: 10.1007/s13369-022-07539-1] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/28/2022]
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Chen P, Wang H, Su J, Tian Y, Wen S, Su B, Yang C, Chen B, Zhou K, Yan C, Shi Y. Recent Advances on High-Performance Polyaryletherketone Materials for Additive Manufacturing. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2022; 34:e2200750. [PMID: 35385149 DOI: 10.1002/adma.202200750] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/24/2022] [Revised: 03/21/2022] [Indexed: 06/14/2023]
Abstract
Polyaryletherketone (PAEK) is emerging as an important high-performance polymer material in additive manufacturing (AM) benefiting from its excellent mechanical properties, good biocompatibility, and high-temperature stability. The distinct advantages of AM facilitate the rapid development of PAEK products with complex customized structures and functionalities, thereby enhancing their applications in various fields. Herein, the recent advances on AM of high-performance PAEKs are comprehensively reviewed, concerning the materials properties, AM processes, mechanical properties, and potential applications of additively manufactured PAEKs. To begin, an introduction to fundamentals of AM and PAEKs, as well as the advantages of AM of PAEKs is provided. Discussions are then presented on the material properties, AM processes, processing-matter coupling mechanism, thermal conductivity, crystallization characteristics, and microstructures of AM-processed PAEKs. Thereafter, the mechanical properties and anisotropy of additively manufactured PAEKs are discussed in depth. Their representative applications in biomedical, aerospace, electronics, and other fields are systematically presented. Finally, current challenges and possible solutions are discussed for the future development of high-performance AM polymers.
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Affiliation(s)
- Peng Chen
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
| | - Haoze Wang
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
| | - Jin Su
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
| | - Yujia Tian
- Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore, 639798, Singapore
| | - Shifeng Wen
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
| | - Bin Su
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
| | - Cao Yang
- Department of Orthopaedics, Union Hospital, Tongji Medical College, Huazhong University of Science and Technology, Wuhan, 430022, China
| | - Binling Chen
- College of Engineering, Mathematics and Physical Science, University of Exeter, Exeter, EX4 4QF, UK
| | - Kun Zhou
- Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore, 639798, Singapore
| | - Chunze Yan
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
| | - Yusheng Shi
- State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China
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Thermoplastic Extrusion Additive Manufacturing of High-Performance Carbon Fiber PEEK Lattices. CRYSTALS 2021. [DOI: 10.3390/cryst11121453] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/05/2023]
Abstract
Polyetheretherketone (PEEK) has been the focus of substantial additive manufacturing research for two principal reasons: (a) the mechanical performance approaches that of aluminum at relatively high temperatures for thermoplastics and (b) the potential for qualification in both the aerospace and biomedical industries. Although PEEK provides outstanding strength and thermal stability, printing can be difficult due to the high melting point. Recently, high-temperature soluble support has enabled the printing of lattices and stochastic foams with overhanging features in these high-performance carbon fiber thermoplastics, in which density can be optimized to strike a balance between weight and strength to enhance performance in applications such as custom implants or aerospace structures. Although polymer powder bed fusion has long been capable of the combination of these geometries and materials, material extrusion with high-temperature sacrificial support is dramatically less expensive. This research provides a comprehensive mechanical analysis and CT-scan-based dimensional study of carbon fiber PEEK lattice structures enabled with high-temperature support and including model validation.
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