Efficient fabrication of lightweight high-strength carbon fiber reinforced PEEK with node-reinforced truss

Carbon fiber-reinforced polyetheretherketone (CF/PEEK) composite offer lightweight, high strength and toughness by combining benefits of resin and fiber materials. However, current shaping methods face challenges such as forming difficulties, inconsistent shapes, and significant mechanical damage. Herein, a CF/PEEK composite thermoforming device were designed. Thermoforming device employs two heating molds (crimping mold at 310°C and roll pipe mold at 400°C) and a coiling roller operating at 45 rpm to enable automatic and efficient continuous production of composite pipes with diameters ranging from 3 to 5 mm. High-strength composite pipes retain excellent thermal stability during shaping, with commendable mechanical properties-tensile strength of 1467 N (decrease of 8.8 %) and specific stiffness of 1.61 × 10 6 N·m/kg, 35-fold increase. Furthermore, stronger braided winding points were introduced into hollow CF/PEEK truss to enhance their strengths, with radial compression strength of node-reinforced truss structure is 550 N (improved by 151 % compared with that of a single composite pipe). This node-reinforced hollow CF/PEEK truss, with its ultra-lightweight and high tensile/compressive strength, significantly expands application potential of CF/PEEK composite materials.