TY - JOUR
T1 - Tailoring viscosity and processability properties of PEEK/PEI blends for 3D printing
T2 - The influence of molecular weight
AU - Bozkurt, Yunus Emre
AU - Kıncal, Cem
AU - Solak, Nuri
AU - Cebeci, Hulya
N1 - Publisher Copyright:
© 2025 Elsevier Ltd
PY - 2025/12
Y1 - 2025/12
N2 - High-performance thermoplastics such as PEEK and PEI are widely used in advanced engineering applications due to their exceptional thermal and mechanical properties. Blending these polymers offers a route to enhance material performance and processability, particularly in additive manufacturing. However, limited printability and phase compatibility continue to hinder their broader application in 3D printing. This study investigates the influence of PEEK molecular weight and viscosity on the thermal, rheological, and mechanical behavior of PEEK/PEI blends, emphasizing their suitability for Fused Filament Fabrication (FFF). Blends were prepared at various weight ratios (80/20–20/80) using three grades of PEEK151G, PEEK381G, and PEEK450G, each with distinct molecular characteristics. Results show that blends incorporating the low-viscosity, low-molecular-weight PEEK151G exhibit significantly improved tensile strength, reduced melt viscosity, and enhanced 3D printability, effectively addressing common issues such as warping and delamination. These findings demonstrate that careful selection of PEEK molecular properties can overcome key processing limitations. The study provides new insight into structure–property–process relationships in high-performance polymer blends and highlights the potential of PEEK/PEI systems as a platform for advanced 3D printing applications in aerospace and related fields.
AB - High-performance thermoplastics such as PEEK and PEI are widely used in advanced engineering applications due to their exceptional thermal and mechanical properties. Blending these polymers offers a route to enhance material performance and processability, particularly in additive manufacturing. However, limited printability and phase compatibility continue to hinder their broader application in 3D printing. This study investigates the influence of PEEK molecular weight and viscosity on the thermal, rheological, and mechanical behavior of PEEK/PEI blends, emphasizing their suitability for Fused Filament Fabrication (FFF). Blends were prepared at various weight ratios (80/20–20/80) using three grades of PEEK151G, PEEK381G, and PEEK450G, each with distinct molecular characteristics. Results show that blends incorporating the low-viscosity, low-molecular-weight PEEK151G exhibit significantly improved tensile strength, reduced melt viscosity, and enhanced 3D printability, effectively addressing common issues such as warping and delamination. These findings demonstrate that careful selection of PEEK molecular properties can overcome key processing limitations. The study provides new insight into structure–property–process relationships in high-performance polymer blends and highlights the potential of PEEK/PEI systems as a platform for advanced 3D printing applications in aerospace and related fields.
KW - 3D printing
KW - Miscible polymer blend
KW - Polyetheretherketone
KW - Polyetherimide
UR - https://www.scopus.com/pages/publications/105020902181
U2 - 10.1016/j.mtcomm.2025.113826
DO - 10.1016/j.mtcomm.2025.113826
M3 - Article
AN - SCOPUS:105020902181
SN - 2352-4928
VL - 49
JO - Materials Today Communications
JF - Materials Today Communications
M1 - 113826
ER -