Assessments and investigation of process parameter impacts on surface roughness, microstructure, tensile strength, and porosity of 3D printed polyetherether ketone (PEEK) materials

• Impacts of nozzle temperature on the mechanical properties • Advantages of AM over Traditional manufacturing • Material properties of PEEK in dental application Additive manufacturing (AM) is emerging as a competitive technology with promising applications across various sectors, including biomedical, automotive, construction, and dental implants. This study investigates the influence of key process parameters on the surface roughness, microstructure, tensile strength, and porosity of Polyether Ether Ketone (PEEK), a high-performance thermoplastic used in dental prosthetics. Traditionally, metals and ceramics have been the standard for dental restorations, but advancements in computer-aided design (CAD) and computer-aided manufacturing (CAM) have improved accuracy, particularly for implant-supported prostheses. However, conventional methods like CAD-milling face challenges such as material waste and tool wear. AM techniques, such as fused deposition modeling (FDM), offer a solution by constructing objects layer by layer, minimizing waste. This research explores the effects of nozzle temperature on the mechanical properties of 3D-printed PEEK, emphasizing its role in optimizing performance and minimizing issues like porosity. Key factors like surface roughness and microstructure are highlighted as critical to the biocompatibility and longevity of dental restorations. The study identifies the optimal nozzle temperature range for PEEK 380-440°C, noting that deviations from this range lead to compromised mechanical properties. Overall, the findings provide valuable insights into optimizing the AM process for PEEK in dental applications and suggest that further biological and chemical studies are necessary to fully realize the material's potential in replacing traditional dental restoration materials.