Ultra High Performance 3D Printed Materials: Strength, Temperature, and Applications

PEEK ultra high performance 3D printed part: image source https://www.3dxtech.com/pages/jigs-fixtures-tooling

Understanding Ultra High Performance 3D Printed Materials

Ultra high-performance 3D printed materials have transformed advanced manufacturing by offering superior mechanical properties, heat resistance, and chemical stability. These materials, including PEEK, PEKK, PEKK-A, TPI, PEI, PI, PPSU, and PAEK, are essential for industries such as aerospace, medical, and automotive, where strength and durability are critical. Selecting the right material requires evaluating price, ease of printing, temperature requirements, crystallinity alignment, annealing needs, and end-use applications.

Comparison of Ultra High Performance 3D Printing Materials

-Material Properties and Printing Requirements

The table below compares key attributes of these materials, including printing difficulty, temperature needs, and performance factors.

Material	Price ($/kg)	Print Difficulty (1-10)	Bed Temp (°C)	Chamber Temp (°C)	Hot End Temp (°C)	Strength (MPa)	Glass Transition Temp (°C)
PEEK	400-700	9	120-140	80-150	360-400	90-100	143
PEKK	500-800	8	120-140	80-150	340-380	80-100	162
PEKK-A	450-750	8	120-140	80-150	340-380	80-100	160
TPI	600-1000	10	120-150	100-180	380-420	90-120	250
PEI	200-300	7	110-140	60-100	320-370	70-90	217
PI	500-900	9	120-140	100-180	360-400	80-110	250
PPSU	150-250	6	100-130	50-100	310-350	55-80	220
PAEK	450-800	8	120-140	80-150	340-380	85-110	162

-Strength vs. Temperature Performance

A graphical representation of the relationship between material strength and glass transition temperature highlights the suitability of each material for high-performance applications.

Crystallinity Alignment and Annealing Considerations

https://www.aon3d.com/material-science/peek-3d-printing-temperatures/

• Crystallinity Alignment: High-performance polymers like PEEK and PEKK require precise crystallinity control to maintain mechanical properties. Printing in a heated chamber helps align polymer chains for maximum strength.

• Annealing: Some materials, like PEEK and PEKK, benefit from post-print annealing to improve mechanical properties and reduce residual stress. Annealing at 200-250°C enhances crystallinity and improves durability.

  

  https://www.aon3d.com/material-science/peek-3d-printing-temperatures/

Use Cases for Ultra High-Performance Materials

• Aerospace: PEEK, PEKK, and TPI are widely used for lightweight, heat-resistant components such as brackets, ducts, and structural supports.

• Medical: PEEK and PEI are commonly used in orthopedic implants, dental applications, and surgical instruments due to biocompatibility.

• Automotive: PPSU and PAEK offer high heat and chemical resistance, making them ideal for under-the-hood components and fuel system parts.

• Electronics: PI and PEI are favored for insulating components in high-temperature environments.

Conclusion

Ultra high-performance 3D printed materials enable cutting-edge applications that demand strength, thermal stability, and chemical resistance. Choosing the right material depends on temperature requirements, printability, mechanical properties, and cost. As advancements continue, these materials will play an even more significant role in manufacturing, helping industries push the boundaries of design and functionality.

Sources

1. Victrex - PEEK for Additive Manufacturing

2. 3DXTech - Ultra Performance Filaments

3. 3D4Makers - Ultra Performance Filaments