Optimization window of printing parameters for specific strength and energy consumption in PEEK additive manufacturing

Fused Filament Fabrication (FFF) is a contemporary rapid prototyping process. Due to the flexibility, simplicity, and low cost of the FFF, significant attention has been paid to fabricating tailored parts in industries that utilize the Polyetheretherketone (PEEK) polymer, such as biomedical and aerospace. This work aspires to assess the effects of nozzle temperature (NT), printing speed (PS), and layer thickness (LT) on the specific ultimate tensile strength (Suts) and energy consumption (Sec) of PEEK parts produced through 3D printing. Analysis of variance (ANOVA) and second-order mathematical models are used to analyze the outcomes and tendencies of the parameters and their relationships with Sec and Suts. The ANOVA, perturbation and interaction plots revealed that the LT·PS, LT·LT, NT, and NT·NT are the key factors in determining Suts. In contrast, the LT·LT dominated in Sec, followed by PS and NT·PS factors. Finally, a desirability analysis was conducted to determine the optimal parameter settings, prioritizing the maximization of Suts and secondarily the minimization of Sec. The optimal combination, 0.154 mm LT, 420°C NT, and 30 mm/s PS, yielded superior process performance, achieving a Sec below 0.4 MJ·cm3/g and an Suts above 50 MPa·cm3/g.