Investigation on PEEK fabrication using mask-image-projection-based stereolithography

This paper presents the findings of an initial study of the fabrication of polyetheretherketone (PEEK) components based on the mask-image-projection-based Stereolithography (MIP-SL) process. PEEK is a semicrystalline thermoplastic with excellent mechanical and chemical resistance properties that are retained to high temperatures. It has been extensively used in the aerospace, automotive, biomedical, and chemical process industries. The fabrication process based on the MIP-SL includes both green-part fabrication and the sintering of fabricated green parts. In the green part fabrication, the challenges of recoating viscous composite slurry are discussed. A prototype system has been developed for the fabrication of green-parts with complex shapes and small features. Based on the fabricated green-parts, the challenges in the sintering process for achieving desired functionality are discussed. The test results on the sintered PEEK components have also been presented. Future work based on the study has been identified.