Environment control in additive manufacturing of high-performance thermoplastics

An expansion of the high-temperature/high-performance polymer 3D printing feedstock palette is critical for the adoption of the technology in more aerospace applications. Open-source printers are a potential platform for the insertion of new materials to the printing palette. However, as-purchased, they are not capable of printing high-temperature polymers. To address this, we developed an open-source-based 3D printer with increased environment controls. These include an enclosure and part heating using infrared energy focused on the printed part to keep it close to the desired temperature, while the printer components stay within their design operating ranges. This enables printing of high-temperature polymers while preventing damage to the machine. The effectiveness of this approach is demonstrated by printing polyetherimide parts ( T g = 217 °C). The temperature of the part as well as temperatures at various locations in the build chamber is monitored and assessed. We then evaluate the overall success of the approach by showing the relationship between part temperature and final properties such as surface flaws, tensile strength, and interfacial bonding.