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<p>The limited crystallinity of additively manufactured amorphous polyetherketoneketone (PEKK) parts restricts their mechanical strength and thermal stability, posing a challenge for broader industrial adoption, particularly in high-performance sectors such as aerospace. In this study, we present a rapid and effective annealing protocol specifically designed to enhance the crystallinity of amorphous PEKK parts fabricated via material extrusion (MEX), without compromising structural integrity. A combined framework integrating differential scanning calorimetry (DSC) and finite element analysis (FEA) was employed to systematically define optimal annealing conditions, identifying 210&#xa0;℃ for 30&#xa0;min as the most effective treatment. This optimized approach increased relative crystallinity from 1.6% to 28.9%, leading to a 29.5% improvement in tensile strength, a 17.3% increase in flexural strength, and a notable 51.4&#xa0;℃ rise in heat deflection temperature. Morphological characterization using scanning electron microscopy (SEM) confirms the transition to a semi-crystalline microstructure with enhanced thermal and dimensional stability. The results establish a scalable, time-efficient pathway for post-processing 3D-printed PEKK, bridging the gap between the ease of amorphous processing and the superior performance of semi-crystalline systems. This work significantly advances the potential of additive manufacturing for high-temperature, load-bearing applications, offering a practical solution to a critical challenge in materials engineering.</p>

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Crystallization engineering of 3D-printed PEKK: rapid post-processing route for superior strength and thermal stability

  • 期刊论文

  • 发表日期：

    2025年8月20日

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  • Farshad Malekpour,
  • Mehdi Hojjati

摘要

The limited crystallinity of additively manufactured amorphous polyetherketoneketone (PEKK) parts restricts their mechanical strength and thermal stability, posing a challenge for broader industrial adoption, particularly in high-performance sectors such as aerospace. In this study, we present a rapid and effective annealing protocol specifically designed to enhance the crystallinity of amorphous PEKK parts fabricated via material extrusion (MEX), without compromising structural integrity. A combined framework integrating differential scanning calorimetry (DSC) and finite element analysis (FEA) was employed to systematically define optimal annealing conditions, identifying 210 ℃ for 30 min as the most effective treatment. This optimized approach increased relative crystallinity from 1.6% to 28.9%, leading to a 29.5% improvement in tensile strength, a 17.3% increase in flexural strength, and a notable 51.4 ℃ rise in heat deflection temperature. Morphological characterization using scanning electron microscopy (SEM) confirms the transition to a semi-crystalline microstructure with enhanced thermal and dimensional stability. The results establish a scalable, time-efficient pathway for post-processing 3D-printed PEKK, bridging the gap between the ease of amorphous processing and the superior performance of semi-crystalline systems. This work significantly advances the potential of additive manufacturing for high-temperature, load-bearing applications, offering a practical solution to a critical challenge in materials engineering.