PAEK Filament Extrusion at Lower Temperatures to Reduce Warping
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Solution Overview
Problem
Existing additive manufacturing processes using poly-aryl-ether-ketones require high extrusion and build environment temperatures, leading to part warping and poor dimensional tolerances, necessitating expensive and complex printers with active temperature control systems.
Innovation Solution
An additive manufacturing process using compositions with specific melt viscosities (200-1500 Pa.s) extruded at 330°C or less and a build environment temperature of 85°C or less, allowing for the use of simpler, less expensive printers without active heating systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high extrusion temperatures and high build environment temperatures are used to process poly-aryl-ether-ketone compositions, then the material can be successfully extruded and deposited, but the printed parts experience thermal contraction and warping resulting in poor dimensional tolerances
Solution Approach 1:
The patent modifies the chemical composition parameters of the poly-aryl-ether-ketone to achieve optimal melt viscosity (200-1500 Pa.s at 320°C and 100 s⁻¹ shear rate). This parameter optimization allows the material to be processed at lower temperatures while maintaining extrudability, thereby reducing thermal contraction and improving dimensional stability of printed parts
Solution Approach 2:
The patent creates composite formulations by blending different poly-aryl-ether-ketone types (PEEK, PEKK, PEK) in specific ratios. These composite materials combine the advantages of individual polymers to achieve the target viscosity range and glass transition temperature (80-160°C), enabling lower temperature processing while maintaining material performance and dimensional accuracy
2Manufacturing precision
If high build environment temperatures (over 100°C) are maintained to prevent warping, then dimensional accuracy improves, but the printer requires expensive and complex engineering solutions including active liquid cooling and physical isolation of components
Solution Approach 1:
The patent enables the use of standard, affordable FFF printers without specialized high-temperature components. By optimizing material viscosity and processing at lower temperatures, the invention makes poly-aryl-ether-ketone printing accessible on conventional equipment that lacks active cooling systems and high-temperature isolation features
Solution Approach 2:
The patent changes the processing temperature parameters from conventional high-temperature FFF (requiring heated chambers over 100°C) to lower temperatures enabled by the optimized material composition. This parameter change eliminates the need for complex temperature control systems, heated chambers, and protective cooling infrastructure
3Ease of manufacture
If standard printers without active heating systems are used to reduce cost and complexity, then printer affordability improves, but the ability to maintain consistent build environment temperature for high performance printing is compromised
Solution Approach 1:
The optimized poly-aryl-ether-ketone composition is designed to self-regulate during printing at lower temperatures, with the material's inherent viscosity and thermal properties enabling successful deposition and bonding without requiring active heated chamber maintenance. The material formulation compensates for temperature fluctuations that would otherwise require expensive active heating control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of dimensionally stable three-dimensional parts with minimal warping using standard printers, maintaining acceptable mechanical properties and dimensional accuracy.
Implementation Method 1
providing a composition comprising at least one poly-aryl-ether-ketone (PAEK) having a melt viscosity from about 200 Pa.s to about 1500 Pa.s, according to ASTM D3835-16, measured at a temperature of 320°C and at a shear rate of 100 s-1
Implementation Method 2
Since materials typically expand when heated and contract when cooled, there is a natural tendency for this deposited polymer layer to contract as it cools to be in equilibrium with the build environment temperature
Implementation Method 3
ideally close to the glass transition temperature of the compositions comprising poly-aryl-ether-ketone(s)
Data Source
AI summary
The invention relates to an additive manufacturing process by extrusion for forming a three-dimensional part in an additive manufacturing machine having a build environment, the process comprising: - i) providing a composition comprising at least one poly-aryl-ether-ketone (PAEK) having a melt viscosity from about 200 Pa.s to about 1500 Pa.s, according to ASTM D3835-16, measured at a temperature of 320°C and at a shear rate of 100 s-1, by capillary rheology using a 1 mm diameter, 15 mm long die; - ii) extruding the composition in the build environment at an extrusion temperature equal to 330°C or less, to form an extruded part section; and, - iii) cooling the extruded part section in the build environment. The invention also relates to a filament and its use in said additive manufacturing process and the corresponding object obtainable from said additive manufacturing process.