Polyetheretherketone (PEEK*) Polymer leader Victrex is preparing new materials for additive manufacturing (AM). The first is a high-strength material for laser sintering (LS) with a low powder renewal rate, thus improving the recycling of unsintered powder. The second is wire, which has a higher Z-axis strength than the existing polyaryletherketone (PAEK)* material, and better thermal fuse forming (FF) printability. Detailed technical results are expected to be announced in September 2018 at the Biennial Conference of Additive Manufacturing at the University of Exeter Laminated Manufacturing Center (CALM).

Vickers CEO Jakob Sigurdsson commented: “The new generation of Victrex additive manufacturing PAEK materials marks a decisive step forward for us to change multiple applications, including aerospace and medical. This exciting development is based on the continued intensive R&D of Victrex and the excellent collaboration of Victrex-led companies and institutional alliances that seek to innovate. Through this alliance, we have seen demonstrations. Parts show how additive manufacturing processes can be combined with high-performance materials to transform thinking and create truly innovative parts based on more design possibilities."

The advantages of additive manufacturing are reduced cost, reduced time to market, and the ability to make parts that are too complex for traditional manufacturing processes. The current PAEK materials on the market, although used in some additive manufacturing applications, are inherently designed for traditional manufacturing methods such as machining and injection molding. Because of this, some of the properties of the material are not the best match for the additive manufacturing process. The first generation of PAEK materials used for laser sintering has a very low recovery rate, requiring a new powder to almost completely refresh the print bed, while the PEEK wire used for thermal fuse forming has poor interlayer bonding, resulting in a decrease in strength in the Z-axis direction. The new polymer grade developed by Victrex exhibits an encouragingly low renewal rate in powder laser sintering (increased recovery of unsintered powder), achieving similar mechanical properties to new powders, showing in thermal fuse formation Good mechanical properties and printability.

Victrex chief scientist John Grasmeder explains: “Breakthrough technology is paving the way for the exciting future of PAEK. The recycling of powders for laser sintering using the new polymer grades developed by Victrex is progressing well. Partially recycled powders have no significant loss in performance when producing test components. We believe that all non-sintered powders recovered after one build run may be reused. This will result in a significant reduction in material costs, in contrast, Up to 40% of the current polyaryletherketone materials are wasted and cannot be recycled."