标题: 3D Printing High-Performance Carbon-Fiber-Reinforced PEEK Composite Pellets by Screw-Extrusion Additive Manufacturing [打印本页] 作者: admin 时间: 2026-10-27 15:34 标题: 3D Printing High-Performance Carbon-Fiber-Reinforced PEEK Composite Pellets by Screw-Extrusion Additive Manufacturing Source: Additive Manufacturing Technology (3D Printing) Branch of the Chinese Mechanical Engineering Society
Contributors: Lu Siwei and Li Dichen
Contributing institution: State Key Laboratory for Precision Micro/Nano Manufacturing Technology, Xi'an Jiaotong University
Lightweight, high-strength carbon-fiber-reinforced polyether ether ketone (PEEK-CF) composites are well suited to applications that demand strength while being sensitive to weight. Traditional filament-based 3D printing, however, is limited in throughput and reinforcement loading, leaving a large gap between application requirements and achievable strength. To address this, Professor Li Xiping and colleagues at Zhejiang Normal University used a custom screw-extrusion 3D printer to produce PEEK-CF parts with different fiber contents (5 wt%, 10 wt%, 20 wt%, and 30 wt%). They comprehensively evaluated the parts' mechanical properties and investigated the effects of heat treatment and hot isostatic pressing.
Figure 1 shows the custom screw-extrusion 3D printer for PEEK-CF composites. It can directly form parts from composite pellets and successfully processed pellets with fiber content as high as 30%, further increasing the fiber loading possible in PEEK-CF composites.
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Figure 1. Screw-extrusion 3D printer: (a) design schematic; (b) physical printer; (c) extrusion screw; (d) heat-resistant folding baffle; (e) heater mounted at the rear of the chamber; and (f) printed samples and polyimide stickers on the heated bed.
Figure 2 shows the mechanical properties of 3D-printed pure PEEK and PEEK-CF parts. Compared with pure PEEK, higher carbon-fiber content increased strength and modulus but reduced impact strength. Notably, PEEK-30CF reached a tensile strength of 190.5 MPa and an elastic modulus of 23.0 GPa; its tensile strength was more than twice that of pure PEEK (92.8 MPa). PEEK-30CF also achieved the highest flexural strength (271.7 MPa) and flexural modulus (23.3 GPa).
At elevated temperatures, the tensile strength of PEEK-20CF gradually decreased as temperature rose. Nevertheless, the printed PEEK-CF composite retained excellent high-temperature strength: its tensile strength exceeded 105 MPa at 150°C. This is comparable to the room-temperature strength of injection-molded pure PEEK and other FFF-printed PEEK-CF composites. Further treatment of PEEK-30CF specimens showed a slight improvement from heat treatment. After hot pressing, tensile strength and modulus reached 218.5 MPa and 29.4 GPa, respectively, moving closer to the strength of injection-molded parts.
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Figure 2. Mechanical properties of 3D-printed PEEK-CF parts at different fiber contents: (a) tensile strength and elastic modulus; (b) flexural strength and modulus; (c) impact strength; and (d) tensile strength of PEEK-20CF at elevated temperatures up to 250°C.
The study successfully printed PEEK-CF composite pellets with up to 30% fiber using a custom screw-extrusion printer, achieving excellent tensile strength of 190.5 MPa. The printed composite also retained outstanding mechanical strength at elevated temperatures, reaching 64.1 MPa at 250°C. Annealing and hot isostatic pressing can further increase crystallinity and reduce porosity, improving mechanical properties. The research demonstrates the potential of screw-extrusion 3D printing for high-performance PEEK-CF, could inspire new approaches to PEEK-CF feedstock design, and may lead to a paradigm shift in additive manufacturing of high-performance thermoplastic composites.
Reference
Z. Hu, J. He, W. Chen, W. Liu, J. Ding, C. He, S. Wang, F. Ning, X. Li, “High-performance carbon fiber reinforced polyether-ether-ketone composite pellets 3D-Printed via screw-extrusion additive manufacturing,” Composites Science and Technology 246 (2024) 110362. https://doi.org/10.1016/j.compscitech.2023.110362
AI-translated from an article by Xiaoruanxiong on Nanjixiong, originally published on 2026-10-26. Text and images retain the original source attribution. Read the original Chinese article
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