![]() ![]() For 3D printing to become more accurate often involves slowing the print, which currently makes machining the better choice on larger production scales. Therefore, PEEK has a long way to go before it becomes the chosen manufacturing method for precision components such as grub screws. Despite 3D printing being able to achieve complex geometries, shrinkage negatively affects the dimensions of the end product. The main disadvantage of 3D printing PEEK components is that machining parts is much more accurate. Some manufacturers are designing enclosed printers that can control the internal temperature, but for now machining may be the better solution for precision screws. Shrinkage that occurs during the 3D printing process affects the GD&T of finished parts. Machining can result in up to 90% of the original block of material being wasted in some cases. Therefore, additive manufacturing is said to be more environmentally friendly because of the lean production process. One of the main advantages that 3D printing PEEK has over traditional subtractive methods, such as CNC machining, is that it does not involve machining or cutting away sections of the material. There are companies such as Vestakeep who make highly biocompatible, biostable, and x-ray transparent implants, which are said to make the operation and follow-up appointments easier for the patient and the surgeon. For example, 3D-printed PEEK is already very popular with manufacturers in the medical industry for making specialist biocompatible parts which are used as implants and devices in the skull and in the hand. It is highly resistant to heat, chemicals and hydrolysis (hot water and steam), which makes it suitable for more applications than standard plastics. Therefore, once a manufacturer has found a way to 3D print PEEK plastic with a high level of precision, there will be a breakthrough which has the potential to disrupt nearly every industry because thermoplastic such as PEEK has many advantageous material properties. Now with 3D printing, lead times are reduced from 10 weeks to three, which reduced the cost and changed the supply chain. For example, polyamide components such as grab handles and armrests on trains were previously difficult to source with a long lead time. Automated 3D printers could form the basis of Industry 5.0 factories where smart technology could automatically print bespoke engineering components.ģD printers have already helped to reduce the lead times in traditional industries such as the rail industry. It could turn manufacturing into an automated “made to order” process whereby a customer can type their requirements into a website and send their order to a 3D printer in the factory, which automatically completes the order. Therefore, PEEK has the potential to transform production facilities, especially as 3D printers become cheaper, faster, and more reliable. Plus, with the reduction in waste, the running cost compared to machining could be a more cost-effective option. The initial set up cost might be high, but no more expensive than CNC equipment. ![]() Once manufacturers of 3D printers develop technology that can print intricate PEEK products with precision and speed, it will disrupt many industries and impact the future of thermoplastic engineering. Could 3D Printed PEEK Change Engineering? They are currently working on ways to solidify PEEK plastic without it shrinking. ![]() They have been developing methods to minimize vibrations which can potentially cause inconsistencies in the print. There are multiple companies that have developed 3D printers specifically for melting PEEK into an easily workable format. ![]() Shrinking during the cooling process means that a PEEK machine screw would shrink to a smaller size, making the thread ineffective. It then has to cool before it can solidify, and it shrinks as it cools. PEEK is often used in the medical industry, but it has a long way to go before it can be used for precision engineering components, particularly products with tight tolerances such as machine screws The main challenge of 3D printing PEEK products is that the print environment has to reach 343☌ before the plastic can melt in order to be reformed inside the printer. The resistance to heat makes the material appeal to design engineers, but also poses several challenges when it comes to 3D printing. The material properties make it an ideal choice for products in demanding applications in hot temperatures such as bearings and pumps. PEEK is one of the most highly rated polymers due to its mechanical strength and superior resistance to heat, water and chemicals. This is especially true for PEEK plastic, also known as polyether ether ketone. 3D printing is often referred to as one of the most revolutionary technologies of the 21st Century because it has the potential to disrupt nearly every industry. ![]()
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