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08-30-2018

Plastics for 3D Printing

New PAEK Materials as Powder and Filament

Additive Manufactured PAEK Demo Bracket. Left filament-based method, right by laser sintering © 3T-RPD

Victrex plc, Lancashire, UK, has developed new and improved materials for additive manufacturing (AM). The first of these is a high strength material for laser sintering (LS) which attains lower refresh rates, resulting in improved recycling for unsintered powder. The second is a filament with better Z-strength than existing polyaryletherketone (PAEK) materials and better printability for filament fusion (FF).

Advantages over previous materials for 3D printing

The PAEK incumbent materials on the market today, although used in some AM applications, were designed for conventional manufacturing methods, such as machining and injection molding. Because of this, they have some features that aren’t optimal for additive manufacturing processes. A first generation of PAEK material for laser sintering can only be recycled in a very low extent and required nearly full refresh of the printing bed with new powder, and PEEK filaments available for FF have poor interlayer bonding, leading to a loss in Z-strength.

According to the manufacturer the new polymer grades developed by Victrex have shown encouragingly low refresh rates (improves recycle for unsintered powder) with similar mechanical properties in LS, and in FF good mechanical properties and printability. Accordingly, it should be possible to re-use all of the non-sintered powder that is recovered after a build run. This will result in a significant reduction in material costs compared to current PAEK materials where up to 40% of the polymer is wasted and cannot be recycled.

Materials Research in a Network

Victrex is leading a consortium of companies and institutions and was awarded funding from the UK's agency for innovation, Innovate UK, in 2016 to carry out intensive pioneering research and development to advance AM technologies, in particular high-temperature, affordable polymer composites for AM aerospace applications. The other members of the consortium are Airbus Group Innovations, EOS, University of Exeter Center for Additive Layer Manufacturing, E3D-Online, HiETA Technologies, South West Metal Finishing, and 3T-RPD.

The new Victrex PAEK filament and powder tie in with technologies developed by other members of this UK project. EOS has recently released a new automation-ready manufacturing platform for laser sintering of plastic parts on an industrial scale (EOS P 500) with the capability to print high-performance polymers at high temperatures. Selected materials of the consortium are evaluated at EOS R&D facilities for processability on current EOS systems as well as for use with the EOS P 500 platforms. Victrex is planning to continue pre-commercial testing of a new PAEK filament product in conjunction with consortium partner E3D, who has recently commercially released a new water-cooled filament extruder head especially optimized for this new PAEK filament.

Company profile

Victrex Europa GmbH

Langgasse 16
DE 65719 Hofheim (am Taunus)
Tel.: 06192 9649-0
Fax: 06192 9649-48

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