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Journal article
Optimization of Fused Filament Fabrication Process Parameters to Improve the Compressive Properties of PEEK and PEKK Biomaterials
Journal of the mechanical behavior of biomedical materials, v 173, 107203
Jan 2026
PMID: 40987056
Featured in Collection : Research Supported by Drexel Libraries' OA Programs
Abstract
Fused filament fabrication (FFF) is increasingly being adopted to create polymeric orthopedic devices. FFF process parameters determine the mechanical performance of final printed parts; hence, optimizing for appropriate levels of strength is critical for load-bearing applications.
We utilized a Taguchi L-9 orthogonal array to investigate the impact of nozzle temperature (TN), chamber temperature (TCh), layer height (LH), and print speed (PS) on the compressive properties of cylindrical polyether-ether-ketone (PEEK) and polyether-ketone-ketone (PEKK). The printed specimens were examined using optical microscopy, scanning electron microscopy, and differential scanning calorimetry to understand the effect of the printing parameters on their macrostructures.
The optimized parameter combination for the elastic modulus (E) of PEEK and PEKK was 390˚C TN, (190˚C–PEEK, 110˚C–PEKK) TCh, 0.1mm LH, and 1000mm/min PS, with LH and PS having the most impact on their stiffness. For the offset yield strength (YS), the optimized parameters were (410˚C–PEEK, 400˚C–PEKK) TN, (210˚C–PEEK, 150˚C – PEKK) TCh, 0.1mm LH, and (1000mm/min–PEEK, 1500mm/min – PEKK) PS, with TN, TCh, and LH significantly impacting both materials.
Elevated thermal conditions enhanced the strength of both materials; however, in PEEK, this was achieved by slowing down its crystallization kinetics, while in PEKK, it increased tendency for crystallization. The print conditions significantly affected the crystallinity of PEKK but not PEEK. Additionally, the highest E of PEEK and PEKK were 113% and 106% of the expected value of unreinforced PEEK, whereas the highest YS were 132% and 120%, respectively, indicating PEKK’s potential for spinal cage applications.
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Details
- Title
- Optimization of Fused Filament Fabrication Process Parameters to Improve the Compressive Properties of PEEK and PEKK Biomaterials
- Creators
- Abigail Tetteh (Corresponding Author) - Drexel University, School of Biomedical Engineering, Science, and Health SystemsJames Anthony Smith - Drexel University, School of Biomedical Engineering, Science, and Health SystemsHannah Spece - Drexel University, School of Biomedical Engineering, Science, and Health SystemsDaniel Porter - United States Food and Drug AdministrationMatthew Di Prima - United States Food and Drug AdministrationSteven M Kurtz - Drexel University, School of Biomedical Engineering, Science, and Health Systems
- Publication Details
- Journal of the mechanical behavior of biomedical materials, v 173, 107203
- Publisher
- Elsevier
- Number of pages
- 12
- Grant note
- National Science Foundation: 2326537 NSF/FDA Scholar-in-Residence program
This work was funded by the National Science Foundation [grant number 2326537] and supported by the NSF/FDA Scholar-in-Residence program.
- Resource Type
- Journal article
- Language
- English
- Academic Unit
- School of Biomedical Engineering, Science, and Health Systems
- Web of Science ID
- WOS:001577636300002
- Scopus ID
- 2-s2.0-105016614963
- Other Identifier
- 991022093053404721
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- Collaboration types
- Domestic collaboration
- Web of Science research areas
- Engineering, Biomedical
- Materials Science, Biomaterials