Design and Manufacturing of Complex Geometry PEEK Component through Fused Filament Fabrication

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Abstract:

Complex geometry components fabricated through Fused Filament Fabrication in polyether ether ketone exhibit very interesting performances, but they are very difficult to predict. Non-standard mechanical tests allow for estimating a global structural response and do not provide local information about the failure evolution. This work investigates the integration of a Digital Image Processing method with non-standard mechanical test to improve the knowledge of the component performance through the tracking and the analysis of local failures. This way, a targeted redesign of the component can be provided: in this work the component was modified at manufacturing stage by changing the Fused Filament Fabrication infill, and at optimization stage by employing a stress line approach for locally densifying the interior.

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Materials Science Forum (Volume 1187)

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99-112

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April 2026

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