Fused filament fabrication of peek: A review of process-structure-property relationships
Open accessAbstract
Poly (ether ether ketone) (PEEK) is a high-performance engineering thermoplastic polymer with potential for use in a variety of metal replacement applications due to its high strength to weight ratio. This combination of properties makes it an ideal material for use in the production of bespoke replacement parts for out-of-earth manufacturing purposes, in particular on the International Space Station (ISS). Additive manufacturing (AM) may be employed for the production of these parts, as it has enabled new fabrication pathways for articles with complex design considerations. However, AM of PEEK via fused filament fabrication (FFF) encounters significant challenges, mostly stemming from the semi crystalline nature of PEEK and its associated high melting temperature. This makes PEEK highly susceptible to changes in processing conditions which leads to a large reported variation in the literature on the final performance of PEEK. This has limited the adaption of FFF printing of PEEK in space applications where quality assurance and reproducibility are paramount. In recent years, several research studies have examined the effect of printing parameters on the performance of the 3D-printed PEEK parts. The aim of the current review is to provide comprehensive information in relation to the process-structure-property relationships in FFF 3D-printing of PEEK to provide a clear baseline to the research community and assesses its potential for space applications, including out-of-earth manufacturing.
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PEEK is well-suited for extraterrestrial environments, especially Lunar conditions, due to its 3D printability, high glass transition temperature Tg (143°C), and operating temperature (250°C).
“PEEK is particularly well-suited for use in extraterrestrial environments, especially Lunar conditions, due to its 3D printability, high glass transition temperature Tg (143 ◦ C), and operating temperature (250 ◦ C).”
From A comprehensive review of lunar-based manufacturing and construction (2024) · cites this paper as [194]
The Introduction reports a glass transition temperature of 143 °C, a service temperature up to 260 °C, and interest in space applications. The Abstract discusses 3D-printed PEEK for out-of-Earth manufacturing, particularly on the ISS, but also notes significant printing challenges. The cited paper does not establish particular suitability for lunar conditions, and its stated service-temperature figure is 260 °C rather than 250 °C. (LLM, conf=0.88)
Experimental — accuracy not yet measuredPEEK offers high tensile strength (around 100 MPa) and low density (1320 kg/m3).
“It also offers high tensile strength (around 100 MPa) and low density ( 1320 kg/m 3 )”
From A comprehensive review of lunar-based manufacturing and construction (2024) · cites this paper as [194]
The Introduction describes PEEK as having high tensile strength and low specific gravity. Section 3.3 reports 94 MPa for a printed PEEK sample, consistent with “around 100 MPa,” but the passages retrieved from our copy do not give a density of 1320 kg/m³ (searched that value and Table 1 properties). (LLM, conf=0.84)
Experimental — accuracy not yet measuredPEEK meets NASA and ESA's outgassing requirements and has high radiation and chemical resistance.
“meets NASA and ESA's outgassing requirements, high radiation and chemical resistance, and a semi-crystalline structure.”
From A comprehensive review of lunar-based manufacturing and construction (2024) · cites this paper as [194]
The Introduction describes PEEK’s chemical stability, and Section 4 reports that UV exposure had little effect on some mechanical properties. Section 4 also reports irradiation-related deterioration, so it does not establish unqualified high radiation resistance. No passage found states that PEEK meets NASA or ESA outgassing requirements (searched: outgassing, NASA, ESA). (LLM, conf=0.87)
Experimental — accuracy not yet measuredPrinting PEEK is challenging due to its semicrystalline nature, high melting point, and high melt viscosity.
“However, printing PEEK can be challenging due to its semicrystalline nature, high melting point, and high melt viscosity.”
From A comprehensive review of lunar-based manufacturing and construction (2024) · cites this paper as [194]
PEEK's characteristics make it a potential alternative to metals in some applications and a suitable choice for structural and mechanical applications.
“These characteristics make it a potential alternative to metals in some applications and a suitable choice for structural and mechanical applications [194-196].”
From A comprehensive review of lunar-based manufacturing and construction (2024) · cites this paper as [194]
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- Authors
- Zanjanijam, A. R., Major, I., Lyons, J. G., Lafont, U., & Devine, D. M.
- Affiliations
- Athlone Institute of Technology (IE)
- European Space Agency (FR)
- Corresponding author
- Devine, Declan M.
- Venue
- Polymers
- Publisher
- MDPI AG
- Published
- 2020-07-27
- Volume
- 12
- Issue
- 8
- Pages
- 1665
- ISSN
- 2073-4360 (ISSN-L)
- PMC
- PMC7465918
- OpenAlex
- W3044352071
- Cited by
- 240
- References
- 123
- Citations by year
- 2026: 36 · 2025: 44 · 2024: 45 · 2023: 40 · 2022: 42 · 2021: 31 · 2020: 2
- FWCI
- 2.00
- Type
- journal article
- Language
- en
- Open access
- gold
- doi.org
- Licence
- Locations
- Polymers (publishedVersion, cc-by)
- PubMed Central (publishedVersion, cc-by)
- PubMed (publishedVersion)
- DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion, cc-by-sa)
- Research@THEA (submittedVersion, cc-by)
- Funders
- European Space Agency (4000126158/18/NL/FE)
- Topics
- Physical Sciences › Engineering › Automotive Engineering › Additive Manufacturing and 3D Printing Technologies
- Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
- Physical Sciences › Engineering › Building and Construction › Innovations in Concrete and Construction Materials
- Keywords
- PEEK, fused deposition modeling, process-structure-property relationships, semicrystalline polymers, printing parameters, polymer 3D printing, space applications, International Space Station, metal substitution
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