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Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title High-Performance PAEK-PEI Blends investigated using Active-Filament Mixing Fabrication
Author(s) Joshua Green, Daniel Hernandez, Ian Rybak, Joseph McKee
On-Site Speaker (Planned) Joshua Green
Abstract Scope High-performance thermoplastics for high-temperature applications are in increasing demand, with polyetheretherketone (PEEK), a member of the polyaryletherketone (PAEK) family, among the most widely used. However, PAEK polymers remain difficult to process via additive manufacturing due to poor printability and weak interlayer adhesion. This study investigates blends of PAEK and polyetherimide-rich (PEI) thermoplastics fabricated using active filament mixing fabrication (AFMF), a modified fused filament fabrication technique that enables in situ material blending. Tensile specimens were printed in open air and tested parallel and perpendicular to the build direction. Compared to neat PEEK, optimized blends showed improved printability, enhanced tensile properties, reduced warping, and significantly improved interlayer adhesion. These results demonstrate the versatility of AFMF to investigate new blends of thermoplastics and indicates that such blends of PAEK and PEI-rich thermoplastics may be a useful formulation for overcoming the persistent challenges in printing high-performance thermoplastics.
Proceedings Inclusion? Undecided

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