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New PAEK filament optimized for additive manufacturing

Jakob Sigurdsson, Victrex CEO comments: ‘This new generation of Victrex additive manufacturing PAEK filament represents an important step forward for Victrex and we are excited now to work closely with INTAMSYS. Due to excellent cooperation with companies and institutions that pursue innovation in additive manufacturing, such as INTAMSYS, as well as Victrex´s continued research, we have been making sustained progress toward creating truly innovative components based on the design freedom of additive manufacturing, combined with the high performance of PAEK polymers.’

The PAEK-based new VICTREX AM filament has been designed and optimized specifically for additive manufacturing. The excellent mechanical properties of PAEK are in demand for high-performance parts. However, until now they were difficult to be fully realized in 3D printed parts with existing choices such as PEEK and PEKK. For example, repurposing injection molding PEEK into filament fusion additive manufacturing, typically results in weak parts because of poor interlayer bonding. This new material is designed to address this weakness in printing PEEK. According to INTAMSYS´ experience using its manufacturing equipment, the VICTREX AM 200 filament has a higher Z-axis strength and has shown to date up to 80% strength in the XY direction with a better fused filament forming (FFF) printing adaptability than the existing PAEK materials.

INTAMSYS has conducted physical and mechanical performance tests on the new VICTREX PAEK filament material. The tests were performed on different printers including the smart dual nozzle FUNMAT PRO 410 3D Printer. This industrial-grade, high-temperature 3D printer can print parts up to 305*305*406mm, can handle a variety of complex structures, and can print a variety of materials such as PEEK, PEEK-CF, PEKK, PC, PC-ABS and other high-performance materials.

Charles Han, Founder and CEO at INTAMSYS details: ‘Our test results to date have shown that the VICTREX AM 200 filament has a better interlayer adhesion than other PAEK materials on INTAMSYS´ machines. Compared with unfilled PEEK, it is designed with slower crystallisation, lower melt temperature, and a viscosity finetuned to the filament fusion process, such as easier flow in the build chamber after leaving the nozzle. Higher flow in open air (low shear rates) also promotes interlayer bonding and stability during printing. All of this contributes to an improved interlaminar adhesion, easier printing (less shrink and warp), and a better suitability for FDM 3D printing, compared to other similar options, based upon the testing we have done at INTAMSYS up to this point.’

Manifold printed with VICTREX AM 200 filament Source: Intamsys

INTAMSYS is also the first company to be part of Victrex´s proposed filament fusion network supporting this new filament. The network aims to facilitate the use of the innovative high-performance VICTREX AM materials based on PAEK polymers and includes further material solutions specifically developed for use in additive manufacturing technology. These materials are designed for high temperature resistance requirements with excellent mechanical properties for AM parts.

Victrex´s new PAEK AM filament has been developed to support a variety of demanding applications because of its very high wear resistance, high temperature resistance, fatigue resistance and corrosion resistance to fluid/chemical, which when combined have the potential to increase design freedom and production cost efficiency.

About the author

Aditya Chandavarkar

Aditya Chandavarkar

Aditya Chandavarkar is a established entrepreneur with business interests in manufacturing, innovative technology and consulting. He is the co-founder of CNT Expositions and Services (acronym for Catalysing New Technologies), which was subsequently formed by the acquisition of Inkjet Forum India – a leading knowledge sharing platform for inkjet printing technology founded by him. At Inkjet Forum India, Aditya was single handedly responsible for conceptualizing and organizing conferences and educations programs, in the area of digital textile printing and industrial inkjet.