It has a melting temperature (T m) of 343 ☌, glass transition temperature (T g) of 143 ☌, and a service temperature up to 260 ☌. The physical and mechanical properties of PEEK are listed in Table 1. Thanks to its linear aromatic structure ( Figure 1), this high-performance thermoplastic polymer exhibits superior thermal resistance, mechanical performance, low linear expansion coefficient, and chemical stability (soluble only in sulphuric acid at 60 ☌. PEEK was first produced by Imperial Chemicals Industries in 1978, and since then, it has attracted a lot of attention in different industries. Poly(ether ether ketone) (PEEK) is an important member of poly (aryletherketone) (PAEK) family with many excellent characteristics. However, other polymers such as poly(ether imide) (PEI), polycarbonate (PC), polystyrene (PS), polyamide (PA), polypropylene (PP) ,poly(vinyl alcohol) (PVA), polyethylene (PE), polycaprolactone (PCL), polyphenylene sulfide (PPS), and polymer blends have been also studied. The most common polymers that are printed via FFF are acrylonitrile-butadiene-styrene (ABS), and poly(lactic acid) (PLA). This three-dimensional (3D) printing technique offers low manufacturing cost, flexibility in structural design, and supervision-free operation. In FFF process, a polymer filament is continuously fed to a liquefier, it is melted and then extruded through a nozzle to construct the layer-by-layer structure on a heated bed. FFF, also known as fused deposition modelling (FDM), is the most commonly used AM technology for fabrication of thermoplastic polymer parts based on computer-aided design (CAD). However, expensive instruments are required when using SLS, which is a big obstacle for making products. It has been used as a technique to overcome drawbacks of other methods.

SLS employs a laser to sinter a polymer powder as a feedstock material. However, the resin employed must be UV curable, which limits the materials that can be employed using this technique. SLA was the first 3D printing machine developed and typically gives the best resolution. In SLA, a photopolymer resin is cured using an energy source, mostly UV laser, to form a single layer of the desired object. Fabrication of polymeric parts via AM is generally carried out using one of three different processes which are stereolithography (SLA), selective laser sintering (SLS), and fused filament fabrication (FFF). Employing this revolutionary method decreases cycle time and cost of product development. The aim of the current review is to provide comprehensive information in relation to the process-structure-property relationships in FFF 3D-printing of PEEK to provide a clear baseline to the research community and assesses its potential for space applications, including out-of-earth manufacturing.Īdditive Manufacturing (AM) is a technology based on the principle of layer-by-layer manufacturing, which allows the production of complicated polymeric, metallic, and ceramic parts. In recent years, several research studies have examined the effect of printing parameters on the performance of the 3D-printed PEEK parts. This has limited the adaption of FFF printing of PEEK in space applications where quality assurance and reproducibility are paramount. This makes PEEK highly susceptible to changes in processing conditions which leads to a large reported variation in the literature on the final performance of PEEK. However, AM of PEEK via fused filament fabrication (FFF) encounters significant challenges, mostly stemming from the semi crystalline nature of PEEK and its associated high melting temperature. Additive manufacturing (AM) may be employed for the production of these parts, as it has enabled new fabrication pathways for articles with complex design considerations. This combination of properties makes it an ideal material for use in the production of bespoke replacement parts for out-of-earth manufacturing purposes, in particular on the International Space Station (ISS).

Poly (ether ether ketone) (PEEK) is a high-performance engineering thermoplastic polymer with potential for use in a variety of metal replacement applications due to its high strength to weight ratio.

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