Design of a Local Heating System for Cost-Effective Fused Filament Fabrication of PEEK

Additive Manufacturing (AM) of Polyether ether ketone (PEEK) via Fused Filament Fabrication (FFF) presents a versatile and effective solution for producing complex, lightweight, and customized parts with intriguing mechanical properties. PEEK, known for its high-temperature resistance, chemical stability, and biocompatibility, finds applications in diverse fields, from aerospace component manufacturing, benefiting from its lightweight nature to biomedical engineering, requiring patient-specific implants or prostheses. However, AM of PEEK via FFF poses significant challenges, and conventional low-cost 3D printers may not always be well-equipped for this demanding task. In the present study, a low-cost solution was proposed and evaluated through simulations and experimental measurements to enhance the performance of a 3D printer valued at less than $ 6.000. The solution entails designing an accessory that utilizes the printer’s second nozzle, incorporating a basic aluminum plate. Through simulations and experimental measurements, it is demonstrated that this accessory provides localized heating in the printing area, thereby increasing the average temperature and improving temperature uniformity. Additionally, specimens printed using this proposed solution show no interlayer delamination and exhibit higher crystallinity compared to parts printed on the same machine without the heating plate.