Study on multi-process parameter optimization and forming performance of polyether ether ketone in powder bed fusion

Polyetheretherketone (PEEK), as a typical lightweight and high-performance polymer, has been extensively applied in medical, aerospace, and other fields. Additive manufacturing (AM) of PEEK enables the integrated fabrication of complex components with both structural and functional characteristics. To address the challenges of high processing temperatures and warpage susceptibility in PEEK powder bed fusion (PBF) systems, multi-process parameter optimization and forming performance were investigated. Through simulation of the forming process, the effects of critical parameters such as laser power on the temperature field were revealed. Based on forming process simulations, experiments were conducted to optimize process parameters, establishing correlations between process parameters, tensile mechanical properties, and warpage rate. Excellent mechanical properties, including a tensile strength of 86 MPa and an elongation at break of 3.7%, were achieved, ultimately enabling high-precision additive manufacturing of cranial implants.